WO2019049432A1 - Rotary electric machine manufacturing device and manufacturing method - Google Patents

Abstract

Provided are a rotary electric machine manufacturing device and a rotary electric machine manufacturing method, wherein excellent work efficiency can be obtained by performing work continuously from coil segment formation to coil assembly without requiring constant management of formed coil segments, and equipment can be constructed at a scale commensurate with demand. This rotary electric machine manufacturing device is provided with: a coil segment formation unit which forms a linear wire material of a predetermined length into a predetermined shape comprising a pair of slot insertion parts extending approximately parallel to each other and a bridge part that connects the pair of slot insertion parts; and a coil assembly part which arranges, in an annular shape, the coil segment formed by the coil segment formation part, and assembles the coil. The coil segment formation part and the coil assembly part are configured to continuously perform the formation and assembly for each coil segment on the basis of control information set according to the coil to be manufactured.

Description

Apparatus and method for manufacturing rotating electrical machine

The present invention relates to a manufacturing apparatus of a rotating electrical machine used for manufacturing a rotating electrical machine (rotating electrical machine) such as a motor and a generator, and a method of manufacturing the rotating electrical machine.

A plurality of segments (hairpins) formed by processing a wire into a U shape are respectively inserted into a plurality of slots arranged along the circumferential direction of the stator or rotor as coils of a stator or rotor in a rotating electric machine. A so-called segmented coil is known in which the free ends of the segments are joined together by welding or the like to form a coil.

As a segment forming method of such a segment type coil, in Patent Document 1, a wire rod cut into a predetermined length is sequentially formed into a three-dimensional shape without movement by the first forming die, the second forming die and the forming roller. A method of forming is disclosed.

Japanese Patent Application Publication No. 2004-297863

According to the conventional coil segment forming method disclosed in Patent Document 1, the curved shape of the transition portion of the segment, the width between the slot insertion portions, etc. are all defined by the mold shape (press surface shape) of the mold. Therefore, in order to change the shape of the transition portion and the width between the slot insertion portions, it is necessary to replace the mold each time. Generally, since one coil contains many types of coil segments having different lengths and angles of the transition portion in the U-shape, and the width between the pair of slot insertion portions, when manufacturing one coil, It is necessary to prepare molds of various shapes and to replace these molds each time. In addition, when assembling a coil by combining coil segments of various shapes obtained by molding in this way, it is necessary to manage segments such as which coil segment is used for which part, so that the assembling operation is very expensive. It becomes complicated.

It should be noted that it is possible to reduce the number of mold replacement operations if the segments of the same shape are pre-formed and stocked in large numbers by the same mold, and the stocked segments are taken out as needed. However, since it is necessary to manage segments of various shapes being stocked, the operation becomes complicated in this case as well, and forming too many segments of various shapes also complicates management.

Furthermore, in the prior art, since the coil segment forming operation and the coil assembling operation can not be performed consistently and must be performed independently of each other, the operation efficiency can not be improved.

Therefore, an object of the present invention is to provide an apparatus and a method for manufacturing a rotating electrical machine that can operate consistently from coil segment formation to coil assembly, and can obtain good working efficiency.

Another object of the present invention is to provide a manufacturing apparatus and a manufacturing method of a rotary electric machine which does not require management such as storage and selection of formed coil segments.

Still another object of the present invention is to provide a manufacturing apparatus of a rotating electrical machine capable of constructing a facility of a scale according to demand.

According to the present invention, the manufacturing apparatus of the rotary electric machine comprises a linear wire rod of a predetermined length, a pair of slot insertion portions extending substantially in parallel with each other, and a transition portion connecting the pair of slot insertion portions A coil segment forming portion for forming into a predetermined shape and a coil assembly portion for assembling coils by arranging coil segments formed by the coil segment forming portion in an annular shape. The coil segment forming unit and the coil assembly unit are configured to continuously perform forming and assembly in units of coil segments based on control information set in accordance with a coil to be manufactured.

By forming and assembling coil segments in units of coil segments based on control information set according to the coils to be manufactured, it is possible to perform from forming of coil segments to coil assembly consistently. Work efficiency is greatly improved. In addition, since it becomes unnecessary to store the formed coil segments and to select a required one from the stored coil segments, management becomes very easy.

The coil segment forming portion performs a primary bending portion in which the wire rod is subjected to primary bending in the same plane, and a primary bending formed body in which the wire bending is performed in the primary bending portion. The primary bending portion and the secondary bending portion continue primary bending and secondary bending in each coil segment unit based on the set control information. Preferably, it is configured to

The apparatus further comprises a wire supply unit for supplying a linear wire of a predetermined length, and the wire supply unit, the coil segment forming unit and the coil assembly unit supply, form and assemble the coil segment based on the set control information. It is also preferable to be configured to continuously perform each coil segment unit.

It is also preferable to further include a coil insertion mechanism for pushing the assembled coil assembled in the coil assembly in the axial direction of the assembled coil and inserting it into the slot of the core coaxially arranged with the assembled coil.

In this case, a work supply line for supplying a stator or rotor having a core, and a coil supply line connected to the work supply line and having a coil segment forming portion, a coil assembly and a coil insertion mechanism are provided. It is also preferred that the coil insertion mechanism of the coil supply line is configured to insert the assembled coil into the slot of the core supplied from the work supply line.

In this case, it is more preferable that the coil supply line is unitized, and a plurality of units of the coil supply line are provided according to the demand of the rotating electrical machine. By unitizing the coil supply line in this way, in the early stages of construction of manufacturing facilities, the scale of manufacturing equipment is made small to reduce the initial investment, and the scale is increased according to the increase in demand. It is possible to invest.

The primary bending portion has a plurality of jigs arranged in the same plane and supporting the wire, and a plurality of jigs, and the wire is based on the movement amount set according to the shape condition of the coil segment to be formed. It is also preferable to have a plurality of primary bending drive mechanisms which are respectively moved in the same plane so as to have a predetermined shape.

It is more preferable that the plurality of primary bending drive mechanisms be configured to turn or linearly move the plurality of jigs based on data of the set movement amount.

The secondary bending portions are disposed to face each other in the same plane and intersect each other, and a plurality of pairs of pressing jigs for holding and pressing the transition portion and a plurality of pairs of pressing jigs are coils to be formed. It is also preferable to have a plurality of secondary bending drive mechanisms that are respectively moved in the direction intersecting with the same plane based on the movement amounts respectively set according to the shape conditions of the segments.

More preferably, the plurality of secondary bending drive mechanisms are configured to move the plurality of pairs of pressing jigs on the basis of the set movement amount data.

A direction in which a plurality of secondary bending drive mechanisms move a plurality of pairs of pressing jigs in a direction perpendicular to the above-mentioned same plane and / or in a direction oblique to the above-mentioned same plane It is also preferred that it be configured to form an offset.

In the coil assembly, a plurality of segment holding portions capable of inserting the coil segments radially outward from each other are annularly arranged along the circumferential direction, and a segment arrangement body rotatable around a central axis, and segment arrangement Each time the body rotates a first predetermined angle, one slot inserting portion of the pair of slot inserting portions of each of the plurality of coil segments is guided and inserted into one segment holding portion of the plurality of segment holding portions Guiding the other slot inserting portion of the pair of slot inserting portions to another one of the segment holding portions of the plurality of segment holding portions when rotating from the insertion of one slot inserting portion to the second predetermined angle; It is also preferable to have a guide means configured to be inserted.

According to the present invention, further, according to the method of manufacturing the rotating electrical machine, the linear wire rod having a predetermined length is formed of a pair of slot inserting portions extending substantially in parallel with each other and a connecting portion connecting the pair of slot inserting portions. A coil segment forming step of forming into a predetermined shape, and a coil assembling step of assembling the coils by annularly arranging the coil segments formed in the forming step. The coil segment forming process and the coil assembling process perform forming and assembly continuously in units of coil segments based on control information set according to a coil to be manufactured.

By forming and assembling coil segments in units of coil segments based on control information set according to the coils to be manufactured, it is possible to perform from forming of coil segments to coil assembly consistently. Work efficiency is greatly improved. In addition, since it becomes unnecessary to store the formed coil segments and to select a required one from the stored coil segments, management becomes very easy.

In the coil segment forming process, a primary bending process in which the wire rod is subjected to primary bending in the same plane, and a primary bending formed body bent in the primary bending process is secondary in the direction crossing the above-mentioned same plane. The secondary bending process for bending is provided, and the primary bending process and the secondary bending process are continuously performed for each primary coil segment in the primary bending process and the secondary bending process based on the set control information. It is preferred to do.

The method further comprises a wire feeding step of feeding a linear wire of a predetermined length, and the wire feeding step, the coil segment forming step and the coil assembling step feed, form and assemble the coil segment based on set control information. It is also preferable to carry out the process continuously in units of coil segments.

It is also preferable to further include a coil insertion step of extruding the assembled coil assembled in the coil assembling process in the axial direction of the assembled coil and inserting it into the slot of the core coaxially arranged with the assembled coil.

According to the present invention, coil segments are formed and assembled in units of coil segments based on control information set in accordance with the coils to be manufactured, so that coil segments are consistently formed from coil segments to coil assembly. Work efficiency is greatly improved. In addition, since it becomes unnecessary to store the formed coil segments and to select a required one from the stored coil segments, management becomes very easy.

According to the present invention, there are further provided a work supply line for supplying a stator or rotor having a core, and a coil supply line connected to the work supply line and having a coil segment forming portion, a coil assembly and a coil insertion mechanism. By making this coil supply line as a unit, in the early stages of production, the scale of manufacturing equipment is reduced in size to reduce the initial investment, and the scale of the equipment is expanded according to the increase in demand. It is possible to do

It is a figure which shows roughly a partial structure of the manufacturing apparatus of the rotary electric machine which concerns on one Embodiment of this invention, (a) is a top view, (b) is a side view. It is a principal part perspective view which shows roughly the jig of the initial state of the primary bending part in an embodiment of Drawing 1, and the relation of a wire rod. It is a figure which shows the shape of the primary bending molded object shape | molded by the primary bending part in embodiment of FIG. 1, (a) is a figure which shows the primary bending molded object of small coil width, (b) is large coil width. It is a figure which shows the primary bending shaping | molding of. It is a principal part perspective view which shows the primary bending operation | movement of the wire in embodiment of FIG. 1 in steps. It is a perspective view which shows roughly the structure of the initial state of the primary bending part in embodiment of FIG. It is a top view which shows roughly the structure of the initial state of the primary bending part in embodiment of FIG. It is a top view for demonstrating that the turning center of the movable base in embodiment of FIG. 1 is shifted from the center of a wire. It is a top view which shows the state in the middle of bending operation | movement of the primary bending part in embodiment of FIG. It is a top view which shows the completion state of bending operation | movement of the primary bending part in embodiment of FIG. It is a top view for demonstrating that the turning center of the turning plate which turns the jig | tool located in the outermost side in embodiment of FIG. 1 has shifted from the center of a wire. It is a block diagram which shows roughly the electric constitution of the manufacturing apparatus in embodiment of FIG. It is a flowchart which shows roughly the control process of the whole manufacturing apparatus in embodiment of FIG. It is a flowchart which shows roughly the control process of the bending operation | movement of the primary bending part in embodiment of FIG. It is a disassembled perspective view which shows roughly the structure of the pressing jig of the secondary bending part of the coil segment shaping | molding apparatus in embodiment of FIG. 1, and the position of the primary bending molded object bent by these pressing jigs. It is a figure which shows the moving direction of each pressing jig of the secondary bending part in embodiment of FIG. It is a figure explaining the curve-like bending process (curve shape shaping | molding) process of the transition part of the secondary bending part in embodiment of FIG. 1, and a process of provision of level | step difference shape (crank shape level | step-difference part formation) process. It is a figure explaining the curvature adjustment operation | movement of the secondary bending part in embodiment of FIG. It is a perspective view which shows roughly the whole structure containing the drive mechanism of the secondary bending part in embodiment of FIG. It is a disassembled perspective view which shows the structure containing the drive mechanism of the one side part (left half seen from the front) of the secondary bending part in embodiment of FIG. It is a front view for demonstrating the operation | movement of the drive mechanism of the one side part shown in FIG. 19 of the secondary bending part in embodiment of FIG. It is a disassembled perspective view which shows the structure containing the drive mechanism of the one side part (right half seen from the front) of the secondary bending part in embodiment of FIG. It is a front view for demonstrating the operation | movement of the drive mechanism of the one-side part shown in FIG. 21 of the secondary bending part in embodiment of FIG. It is a flowchart which shows roughly the control process of the bending operation of the secondary bending part in embodiment of FIG. It is principal part sectional drawing which shows the operation | movement which the coil assembly part in embodiment of FIG. 1 guides and inserts a 1st coil segment in a segment holding part. It is principal part sectional drawing which shows the state which the coil assembly part in embodiment of FIG. 1 inserted the front leg of the coil segment to 3rd to the segment holding part. It is principal part sectional drawing which shows the state which the back leg of the 1st coil segment leaves | separates from a guide member, and the coil assembly part in embodiment of FIG. 1 is guided to a segment holding part. The coil assembly in the embodiment of FIG. 1 is mounted on the front legs of the eighth to tenth coil segments with the back legs of the first to third coil segments guided and inserted in the segment holding parts, and the fourth coil segment It is principal part sectional drawing which shows the state which is separated from a guide member and is guided to a segment holding part. It is principal part sectional drawing which shows the state in which the coil assembly part in the embodiment of FIG. 1 inserted the coil segment of the 1st round into a segment holding part. The coil assembly part in the embodiment of FIG. 1 is a fragmentary cross-sectional view showing a state where the front leg of the first coil segment of the second round is inserted into the segment holding part after the coil segment of the first round is inserted into the segment holding part. FIG. It is a perspective view which shows roughly the structure of the segment conveyance means in embodiment of FIG. It is a perspective view which shows roughly the structure which looked at the segment conveyance means in embodiment of FIG. 1 from the back side. It is a perspective view which shows roughly the guide member of the coil assembly part in embodiment of FIG. 1, and the coil segment guided by this guide member. It is an expanded view explaining the assembly order of one type of coil segment assembled by the coil assembly part in embodiment of FIG. It is a perspective view which shows roughly the structure of the whole coil assembly part in embodiment of FIG. It is a perspective view which shows roughly the structure of the extrusion mechanism of the coil assembly part in embodiment of FIG. 1, and a braid | blade adjustment mechanism. It is a partially broken perspective view which shows roughly the structure of a part of braid | blade adjustment mechanism of the coil assembly part in embodiment of FIG. It is a schematic perspective view which shows the detachment prevention means of the coil assembly part in embodiment of FIG. It is a perspective view which shows roughly the structure of the detachment prevention means of the coil assembly part in embodiment of FIG. The manufacturing apparatus of the rotary electric machine of embodiment of FIG. 1 WHEREIN: It is a perspective view which shows roughly the state which connected the workpiece | work support stand and the coil assembly part. The manufacturing apparatus of the rotary electric machine of embodiment of FIG. 1 WHEREIN: It is a disassembled perspective view which shows roughly the structure for inserting an assembly coil in a core. It is a perspective view which shows roughly the state which inserted a part of assembly coil in the manufacturing apparatus of the rotary electric machine of embodiment of FIG. 1 in the insertion guide. It is a perspective view which shows roughly the state in front of the completion of insertion to the core of the assembly coil in the manufacturing apparatus of the rotary electric machine of embodiment of FIG. It is a disassembled perspective view which shows roughly the state which insertion of the assembly coil to the core in the manufacturing apparatus of the rotary electric machine of embodiment of FIG. 1 completed. It is a flowchart which shows roughly the control process of the coil assembly part of embodiment of FIG. It is principal part sectional drawing which shows the state in which the coil assembly part in other embodiment of this invention inserted the 1st and 2nd coil segment in the segment holding part. It is principal part sectional drawing which shows the state in which the front leg of the coil assembly part in the above-mentioned other embodiment to 3rd was inserted in the segment holding part. It is principal part sectional drawing which shows the state from which the coil assembly part in the above-mentioned other embodiment inserts the back leg of the 2nd coil segment into a segment holding part first rather than the back leg of the 1st coil segment. It is principal part sectional drawing which shows the state in which the coil assembly part in the above-mentioned other embodiment inserted the coil segment of the 1st round into a segment holding part. It is a perspective view which shows roughly the structure of the whole coil assembly part in the above-mentioned other embodiment. It is a top view which shows roughly the example of system composition of the manufacture device of rotation electrical machinery of the present invention. It is a top view which shows roughly the other system configuration example of the manufacturing apparatus of the rotary electric machine of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the embodiment described below, a flat wire having a rectangular cross section is described as the wire, but for example, a wire having a round shape, a square shape, a polygonal shape, or a single wire of any other cross sectional shape or a stranded wire Even the present invention is applicable.

As shown in FIG. 1, a manufacturing apparatus 100 of a rotating electrical machine according to an embodiment of the present invention includes a coil segment forming unit 1 and a coil segment formed by the coil segment forming unit 1 along the circumferential direction of the rotating electrical machine. And a coil assembly portion 2 assembled in correspondence with the annularly arranged slots.

The coil segment forming unit 1 has a predetermined shape (for example, a U-shaped shape) in the same plane (in the present embodiment, a horizontal plane) of the wire supply unit 3 and a linear wire of a predetermined length supplied from the wire supply unit 3 ) And a coil segment (primary bending formed body) bent at the primary bending portion 4 in a plane perpendicular to the axis of the coil segment and the above-mentioned plane (in the present embodiment) A shape (for example, a step shape, a crank shape) for bending (forming into a curved shape) in the vertical plane) and for shifting the pair of slot insertion parts of the coil segment mutually in the radial direction of the core And a secondary bending portion 5 (forming a crank-shaped step portion) to be applied.

The wire supply unit 3 includes a bobbin 7 wound with a wire 6 made of a flat wire covered with an insulating layer, a feeding direction changing unit 8 for pulling out the wire 6 from the bobbin 7 and changing the supply direction, and a flat of the wire 6 The correction conveyance part 9 which has a plurality of roller pairs 9a which sandwich and convey a Wise surface, and a plurality of roller pairs 9b which sandwich and convey an edgewise surface of the wire 6, and which corrects distortion in the longitudinal direction A peeling portion 10 for peeling the covering insulating layer at both ends corresponding to a predetermined length of the wire 6 whose strain is corrected, and a cutting portion 11 for cutting the wire 6 having passed the peeling portion 10 at a predetermined length position Have. The peeling part 10 in this embodiment has a structure which peels a coating insulating layer with a laser beam, and the peeling range includes the peeling part of the one-side edge part of the following wire material. Therefore, the cutting part 11 is comprised so that the wire 6 may be cut | disconnected in the center part of the peeling range. In addition, as a peeling part 10, you may use the structure which peels the coating insulation layer of the wire 6 by mechanical cutting or shaving off, without using a laser beam.

The wire 6 bent by the primary bending portion 4, that is, the primary bending molded body bent in a U-shape, is transferred by the transfer mechanism 12 disposed between the primary bending portion 4 and the secondary bending portion 5. It is transferred to the secondary bending unit 5. The transfer mechanism 12 is provided with a pair of chucks (not shown) by an air cylinder, and the pair of chucks are turned by bending of both legs (one pair of slot inserting portions) of the primary bending formed body It stands by in the state where the chuck piece is opened in the coming range. When the chuck portion grips both legs of the primary bending formed body, the transfer mechanism 12 ascends to remove the primary bending formed body from the primary bending portion 4 and transfers it to the secondary bending portion 5. The primary bending molded body transferred by the transfer mechanism 12 is held by the holding member 13 at the ends of both legs. Similar to the transfer member 12, the holding member 13 is configured to hold the pair of slot insertion portions with a pair of chuck portions opened and closed by an air cylinder. In a state in which the transfer mechanism 12 which has delivered the primary bending formed body to the holding member 13 is retracted and the coil end portion (crossover portion) side is opened in space, the bending by the secondary bending portion 5 with respect to this coil end portion Bending is performed including shape forming and formation of a crank-shaped step. In the configuration shown in FIG. 1, the supply direction changing unit 8 of the wire supply unit 3, the correction conveyance unit 9, the peeling unit 10 and the cutting unit 11, and the primary bending unit 4 are in the lateral direction in FIG. The secondary bending portion 5 is disposed in a row, and the secondary bending portion 5 is disposed in the vertical direction (perpendicular direction) in FIG. 1A with respect to the primary bending portion 4, and the coil assembly portion 2 is disposed relative to the secondary bending portion 5. 1 (a), the supply direction changing unit 8, the correction conveyance unit 9, the peeling unit 10, the cutting unit 11, the primary bending unit 4, the secondary bending unit 5, and the coil The assembling portions 2 may be arranged in a line in the lateral direction in FIG. 1 (a). That is, there are no limitations on the layout, as long as the coil formation is completed in a single manufacturing device, in other words, the arrangement of the coil segment forming portion and the coil assembly portion is limited.

Hereinafter, the configuration and bending operation of the primary bending portion 4 will be described in detail.

As shown in FIG. 2, the primary bending portion 4 has a plurality of (here, six) blocks each having a plurality of recessed grooves for supporting the wire 6 of a predetermined length extending linearly with both ends peeled off. Shaped jigs 14A, 14B, 15A, 15B, 16A and 16B. In the figure, the peeling part of the both ends of the wire 6 is displayed by the dot. The rotational movement or linear movement of the jigs 14A, 14B, 15A, 15B, 16A and 16B is numerically controlled (NC control) based on the set control data. In the present specification, “rotational movement” means rotation (pivoting) with respect to the rotational center (pivot center).

In this embodiment, the wire 6 is bent into a U-shape shown in FIG. 3A in the same plane by the primary bending portion 4 to form a primary bending formed body 17A of the coil segment. . The primary bending molded body 17A has an angle (hereinafter referred to as a "shoulder angle") between the connecting portion 17a having a mountain shape having an apex angle (hereinafter referred to as "central angle") having an angle θ1. ) Are connected so as to form an angle θ 2, and they consist of a pair of slot insertion portions 17 b and 17 c extending substantially parallel to each other. The transition portion 17a and the pair of slot insertion portions 17b and 17c are formed to be located on the same plane. The primary bending molded body 17A is an example of a small coil width in which the length of each piece of the crossover portion 17a is as small as L1.

As shown in FIG. 2, the jigs 14A, 14B, 15A, 15B, 16A and 16B in the present embodiment are, in other words, wire members with respect to the bending center line C (bending center line) of the primary bending portion 4. Based on the center position in the axial direction of 6, the same number (three each) is arranged in line symmetry on the left and right sides. The pair of jigs 14A and 14B arranged at the innermost side with respect to the bending center line C performs bending such that the central angle of the crossover portion 17a of the primary bending formed body 17A becomes an angle θ1 by rotational movement. Provided in In practice, the pair of jigs 15A and 15B and the pair of jigs 16A and 16B also rotate together with the pair of jigs 14A and 14B. On the other hand, when the pair of jigs 16A and 16B arranged at the outermost side with respect to the bending center line C and the pair of jigs 15A and 15B next to them are rotated, the shoulder angle becomes the angle θ2 It is provided to perform bending. Depending on the distance m between the jig 14A and the jig 15A and the distance m between the jig 14B and the jig 15B, the length L1 of each piece of the crossover portion 17a of the primary bending formed body 17A shown in FIG. The coil width is defined.

As shown in FIG. 2, the jigs 14A, 14B, 15A, 15B, 16A and 16B are formed by grooves 14A-1, 14B-1, 15A-1, 15B-1 and 16A which are open at the top and penetrate in the lateral direction. It has -1 and 16B-1 respectively. The width w1 of each recessed groove is set to be slightly larger than the width (width in the edgewise direction) w2 of the wire 6 which is a flat wire, whereby the wire 6 is fixed during bending operation in the edgewise direction. The grooves 14A, 14B, 15A, 15B, 16A and 16B are configured to be reliably supported by the grooves. The support configuration of the wire 6 by each jig is not limited to a specific shape, but here, it is accommodated in a recessed groove to restrain movement in the bending direction. The depth d1 of each recessed groove is set to be equal to or greater than the thickness (width in the flatwise direction) d2 of the wire 6. The width w1 of each groove is a width capable of closely accommodating and supporting the wire 6 in order to improve the dimensional accuracy of the primary bending formed body 17A. The width w1 is not variable, and when the width w2 of the wire 6 is changed according to the type of coil, it is necessary to replace the jigs 14A, 14B, 15A, 15B, 16A and 16B. Therefore, the jigs 14A, 14B, 15A, 15B, 16A and 16B are detachably provided to a support member described later by a fixing screw or the like.

In the initial state before the bending of the primary bending portion 4 is started, as shown in FIG. 2, the concave grooves 14A-1, 14B-1 of these jigs 14A, 14B, 15A, 15B, 16A and 16B. , 15A-1, 15B-1, 16A-1 and 16B-1 are set to be aligned with one another. That is, they are the initial positions of the jigs 14A, 14B, 15A, 15B, 16A and 16B.

As shown in FIG. 2, wire rods in the concave grooves 14A-1, 14B-1, 15A-1, 15B-1, 16A-1 and 16B-1 of the jigs 14A, 14B, 15A, 15B, 16A and 16B Edge portions 14A-2, 14B-2, 15A-2, 15B-2, 16A-2 and 16B-2 in contact with the surface on the edgewise side of 6 are insulated at the corners of wire 6 during the bending operation. It is formed in a curved shape so as not to damage the layer. Also, in order to avoid interference with other jigs due to displacement during bending, chamfers 14A-3, 14B-3, 15A are provided on the outer surfaces of the jigs 14A, 14B, 15A, 15B, 16A and 16B. -3, 15B-3, 16A-3 and 16B-3 are respectively formed. In the conventional method of pressing with a pair of molds having a working surface corresponding to the intended bending shape, both sides of the wire, in some cases the entire peripheral surface, are subjected to a pressing pressure, so the insulating layer of the wire is damaged. It was easy to get along. When the bending accuracy was to be increased, the edge of the forming surface was sharpened, but the stress was concentrated there, and the insulating layer was easily damaged. Further, in the method of pressing with a mold, it is not known whether the insulating layer will be damaged unless it is actually pressed, and if there is a problem, it is necessary to redo the production of the mold, resulting in cost increase. . In the present embodiment, since the bending process is performed in the open system in which only the wire 6 is accommodated in the concave groove of the jig as described above, no scratching of the insulating layer of the wire occurs.

In the above description, the jigs 14A, 14B, 15A, 15B, 16A and 16B are concave grooves 14A-1, 14B-1, 15A-1, 15B-1 and 16A which are opened in the upper surface and penetrated in the lateral direction. In this embodiment, the wire 6 is inserted from the upper side into these grooves, but the wire 6 may be inserted into the grooves from the lateral direction. Moreover, although it was set as the structure which restrains and supports the wire 6 by the concave groove of an upper surface opening type | mold during bending operation, this invention is not limited to this. For example, by forming jigs 14A, 14B, 15A, 15B, 16A and 16B into a structure having an insertion hole through which the wire 6 is inserted by forming an overlapping structure, bending the wire 6 by inserting the wire 6 from the lateral direction It is good also as composition which moves and opens an upper or lower jig after completion of primary bending processing.

When the primary bending portion 4 bends the wire 6, first, the wire 6 cut to a predetermined length is a concave groove in which the jigs 14A, 14B, 15A, 15B, 16A and 16B are linearly arranged. It is inserted from above from inside and placed and supported in a bridged state. Next, the bending operation by the primary bending portion 4 is started.

FIG. 4 schematically shows this bending operation by the primary bending portion 4. The figure (a) has shown the state by which the wire 6 is set and supported in the bridge state in the ditch | groove in which the jigs 14A, 14B, 15A, 15B, 16A and 16B were mutually located in a straight line. In this state, the jigs 14A, 14B, 15A, 15B, 16A and 16B are rotationally moved to perform the first bending process of the wire 6 as shown in FIG. Processing is performed to finally form a U-shaped primary bending molded body 17A as shown in FIG.

As described above, in the present embodiment, the six jigs 14A, 14B, 15A, 15B, 16A and 16B are arranged in line symmetry with respect to the bending center line C, and are arranged at line symmetrical positions. Are rotationally moved or linearly moved in line symmetry based on the control data. Therefore, as shown in FIG. 3A, the primary bending molded body 17A formed by the primary bending portion 4 of the present embodiment has a line-symmetrical U shape. By changing the control data to change the amount of rotational movement or linear movement of the jigs 14A, 14B, 15A, 15B, 16A and 16B, it is possible to form primary bending molded articles of various shapes. For example, in the initial state before bending or during bending, the pair of jigs 15A and 15B and the pair of jigs 16A and 16B are linearly moved in the direction away from the bending center line C, and the jig 14A described above is When the second bending process is performed with the distance m between the jig 15A and the jig 15A and the distance m between the jig 14B and the jig 15B increased, as shown in FIG. The length of each piece is L2, and it is larger than the length L1 of each piece of the crossover portion 17a in FIG. 3A (L2> L1), thus producing a linearly symmetrical primary bending molded body 17B having a large coil width. can do. As described above, by changing the amounts (control data) for moving the jigs 14A, 14B, 15A, 15B, 16A and 16B, it is possible to form a primary bending formed body corresponding to coil segments of various shapes. It can be obtained immediately without replacing parts (jig). As described above, although there are multiple types of shape coil segments in one coil of the rotating electrical machine, in the present embodiment, if multiple types of control data are input, each jig is read based on the control data read out. Automatically moves, and multiple types of coil segments (primary bending formed bodies) are continuously produced. For this reason, a plurality of types of coil segments (primary bending formed body) necessary for forming one coil can be manufactured at once without requiring stock management.

As described above, in the present embodiment, a plurality of simple block-shaped jigs 14A, 14B, 15A, 15B, 16A and 16B which do not have a shape corresponding to the bending shape to be formed are formed on one plane (horizontal surface) The primary bending forming body of the coil segment is formed only by rotational movement or linear movement by NC control based on the control data. Therefore, according to the present embodiment, it is not necessary to use a mold having a shape corresponding to the bending shape to be molded as in the prior art, and a plurality of NC-controlled jigs are used, so an expensive mold is required. The manufacturing cost is eliminated and the manufacturing cost of the coil segment is reduced. In addition, when coil segments of various shapes are formed, no work such as mold replacement is required, so there is no downtime due to mold replacement, and work time can be shortened, and work can be achieved. It becomes extremely easy.

Next, the support structure and drive configuration of the jigs 14A, 14B, 15A, 15B, 16A and 16B described above will be described in detail.

As shown in FIGS. 5 and 6, the primary bending portion 4 is a fixed base 18 having a notch at the front (the lower in FIG. 6) and at a central portion centering on the bending center line C; A pair of arc-shaped guide rails 19A and 19B arranged symmetrically about a bending center line C in a front portion on the fixed base 18 and engaged with the guide rails 19A and 19B respectively, these guide rails 19A And 19B, and movable mechanisms 20A and 20B, and a drive mechanism 21 for moving the movable bases 20A and 20B along the guide rails 19A and 19B, respectively.

The guide rails 19A and 19B are configured such that one point on the bending center line C is the center of the arc.

The drive mechanism 21 includes a ball screw portion 22 having a rotation axis in the DX direction along the bending center line C, a nut portion 23 screwed with the ball screw portion 22 and slidable in the DX direction, and a ball screw portion 22. A rotationally movable joint between the slider 25 and the movable bases 20A and 20B, which is fixed to the rotationally driven servomotor 24 and the nut portion 23, and is moved in the DX direction with the rotation of the ball screw portion 22. And arms 26A and 26B connected to each other.

The movable base 20A is disposed along the DU direction, the rotation axis of which is orthogonal to the DX direction, and the driving mechanism capable of changing the distance m between the jig 15A and the jig 14A by linearly moving the jigs 15A and 16A. 27A and a drive mechanism 28A whose rotation axis is disposed in the DY direction parallel to the drive mechanism 27A and which rotationally moves the jig 16A. The movable base 20B is disposed along the DV direction facing the drive mechanism 27A and having its rotation axis orthogonal to the DX direction, and the jigs 15B and 16B are linearly moved to a distance between the jig 15B and the jig 14B. A drive mechanism 27B capable of changing m, a drive mechanism 28B disposed so as to face the drive mechanism 28A and having a rotation axis thereof disposed in the DZ direction parallel to the drive mechanism 27B, and rotating the jig 16B are provided. It is done.

The driving mechanism 27A includes a ball screw portion 29A having a rotational axis in the DU direction, a nut portion 30A screwed with the ball screw portion 29A and slidable in the DU direction, and a servomotor 31A for rotationally driving the ball screw portion 29A. And a slide plate 32A which is fixed to the nut portion 30A and moves in the DU direction as the ball screw portion 29A rotates. A jig 15A is fixed to the slide plate 32A, and a pivot plate 34A having a cam follower 33A is pivotally supported, and a jig 16A is fixed to the pivot plate 34A. The drive mechanism 28A includes a ball screw portion 35A having a rotation axis in the DY direction, a nut portion 36A screwed with the ball screw portion 35A and slidable in the DY direction, and a servomotor 37A that rotationally drives the ball screw portion 35A. And a pivot drive plate 38A fixed to the nut portion 36A and moved in the DY direction with the rotation of the ball screw portion 35A. The pivot drive plate 38A has an engagement recess 39A which engages with the cam follower 33A.

The drive mechanism 27B rotationally drives a ball screw portion 29B having a rotation axis in the DV direction orthogonal to the DX direction, a nut portion 30B screwed in the ball screw portion 29B and slidable in the DV direction, and the ball screw portion 29B. And a slide plate 32B which is fixed to the nut portion 30B and moves in the DV direction as the ball screw portion 29B rotates. A jig 15B is fixed to the slide plate 32B, and a pivoting plate 34B having a cam follower 33B is pivotally supported, and the jig 16B is fixed to the pivoting plate 34B. The drive mechanism 28B includes a ball screw portion 35B having a rotation axis in the DZ direction, a nut portion 36B screwed with the ball screw portion 35B and slidable in the DZ direction, and a servomotor 37B for rotationally driving the ball screw portion 35B. And a pivot drive plate 38B fixed to the nut portion 36B and moved in the DZ direction with the rotation of the ball screw portion 35B. The pivot drive plate 38B has an engagement recess 39B that engages with the cam follower 33B.

As described above, the jigs 14A, 15A and 16A and the drive mechanisms 27A and 28A are provided on the movable base 20A, and rotationally move with the rotational movement of the movable base 20A. In addition, the jigs 14B, 15B and 16B and the drive mechanisms 27B and 28B are provided on the movable base 20B, and rotationally move with the rotational movement of the movable base 20B.

As shown in FIG. 7, on the lower surface of the movable base 20A, two non-illustrated fitting members fitted to the guide rails 19A slide on the guide rails 19A at mutually separated positions along the arc of the guide rails 19A. It is mounted movable. Similarly, on the lower surface of the movable base 20B, two non-illustrated fitting members fitted to the guide rails 19B are slidably attached to the guide rails 19B at mutually separated positions along the arc of the guide rails 19B. ing.

The centers of the arcs of the guide rails 19A and 19B, that is, the centers of rotational movement of the movable bases 20A and 20B, are pivot centers 41 which are one point on the bending center line C, as shown in FIG. In the present embodiment, in the pivotal movement of the movable bases 20A and 20B, the fitting members 40A and 40B of the movable bases 20A and 20B are provided on the rail-shaped guide rails 19A and 19B provided on the fixed base 18. Although they are configured to be fitted and slide respectively, a guide rail having a recessed groove may be provided on the fixed base 18, and a protruding portion provided on the movable bases 20A and 20B may be configured to be engaged with the recessed groove. .

The turning center 41 of the movable bases 20A and 20B is, as shown in FIG. 7, a slight distance t (in the lower side in FIG. 7) from the center line 43 of the wire 6 on the bending center line C. For example, it is set at a position shifted by t = 0.5 mm). The reason is that when the wire 6 is bent in the edgewise direction, expansion of thickness occurs due to the compression action inside the bend, and reduction of thickness due to the tension action occurs outside the bend. Since the change in thickness is larger at the inside of the bend than at the outside, the center of rotation 41 of the movable bases 20A and 20B is deviated inward as described above in order to minimize the expansion and contraction of the wire 6 due to the bending.

Next, the bending operation of the primary bending portion 4 of the present embodiment will be described based on FIG. 6 to FIG.

When the primary bending portion 4 is in the initial state, as shown in FIGS. 6 and 7, the grooves of the jigs 14A, 14B, 15A, 15B, 16A and 16B are in a state in which they are linearly aligned with each other, The linear wires 6 are inserted and placed in the recessed grooves of these jigs and supported in a bridged state.

When the drive mechanism 21 operates from this state, the slider 25 advances in the DX + direction, whereby the movable bases 20A and 20B rotationally move around the turning center 41 via the arms 26A and 26B, respectively. Since the jigs 14A, 15A and 16A and the jigs 14B, 15B and 16B are respectively fixed to the movable bases 20A and 20B, the jigs 14A, 15A and 16A and the jigs 14B, 15B and 16B are the movable base 20A. The wire rod 6 is rotationally moved together with 20B, whereby the wire rod 6 is bent at the bending center line C, and the central angle of the connecting portion 17a is bent to an angle θ1 as a set angle based on the control data. The state after the first bending process by this turning is shown in FIG.

When the central angle becomes the angle θ1, the drive mechanisms 28A and 28B operate, the swing drive plate 38A moves in the DY + direction (see FIG. 6), and the swing drive plate 38B moves in the DZ + direction. Thereby, as shown in more detail in FIG. 10, the engagement recesses 39A and 39B respectively press the cam followers 33A and 33B so that the pivot plates 34A and 34B are centered on the pivot center 44 (see FIG. 10). To turn. The jigs 16A and 16B are rotationally moved by this turning of the turning plates 34A and 34B, and the shoulder angle of the wire 6 is bent until it becomes the angle θ2 as a set angle based on the control data, and the U-shaped bending is completed. Do. The state after the second bending process is shown in FIG.

The pivoting center 44 of the pivoting plates 34A and 34B, that is, the centers of rotational movement (pivoting) of the jigs 16A and 16B is slightly inward t from the center line 43 of the wire 6 as shown in FIG. It is set at a position shifted by 0.5 mm). The reason is that when the wire 6 is bent in the edgewise direction, expansion of thickness occurs due to the compression action inside the bend, and reduction of thickness due to the tension action occurs outside the bend. Since the change in thickness is larger at the inside of the bend than at the outside, the rotation center 44 of the turning plates 34A and 34B, ie, the rotational movement of the jigs 16A and 16B as described above, in order to minimize expansion and contraction of the wire 6 due to bending. The center of the (turning) is bent inwards.

As described above, by changing the distance m between the jig 14A and the jig 15A and the distance m between the jig 14B and the jig 15B, the length of each piece of the crossover portion 17a of the primary bending formed body 17A Can change. By changing the length of each piece of the crossover portion 17a in this manner, the width (coil width) of the U-shaped primary bending molded body 17A can be changed, and a coil segment meeting the requirements can be manufactured. . That is, it is possible to create a primary bend-formed body with a small coil width or a primary bend-formed body with a large coil width. The setting of the distance m is performed by the drive mechanisms 27A and 27B. That is, when the drive mechanisms 27A and 27B operate, the slide plate 32A to which the jig 15A and the jig 16A are attached is linearly moved in the DU direction and the slide plate 32B to which the jig 15B and the jig 16B are attached is By moving linearly in the DV direction, the distance m can be changed. As described above, the cam followers 33A and 33B are fixed to the slide plates 32A and 32B, respectively, and the cam followers 33A and 33B are engaged with the engagement recesses 39A and 39B of the turning drive plates 38A and 38B. Drive mechanisms 28A and 28B operate so that pivoting drive plates 38A and 38B move synchronously with slide plates 32A and 32B. Hereinafter, these synchronous movements are appropriately abbreviated as movements of only the slide plates 32A and 32B.

Although the setting of the distance m may be set before the bending process is started, it is possible until the jigs 16A and 16B themselves turn even during the bending operation. The slide plates 32A and 32B are located at the home position in the initial state before the start of bending, and are configured to move from the home position based on given control data.

FIG. 11 shows the electrical configuration of the manufacturing apparatus in the present embodiment, and FIG. 12 shows the control process of the entire manufacturing apparatus.

As shown in FIG. 11, a human-machine interface (HMI) 45 including an input such as a touch panel and a display means, an input of control data for forming processing of the wire, an instruction to read out the control data stored in the memory, and a memory An instruction to correct the control data stored in the controller, an instruction to start the NC control, an instruction to end the NC control, or the like is input. The HMI 45 is connected to a programmable logic controller (PLC) 46 via Ethernet (registered trademark), and the first NC controller 47 and the second NC controller 48 are connected to the PLC 46 via a high-speed network such as CC-Link. . The PLC 46 has a memory for storing at least control data and control programs for forming coil segments of various shapes, a central processing unit (CPU), and an input / output interface, and the CPU is instructed according to the program. It has a function of transferring control data to the first NC controller 47 and the second NC controller 48. The first NC controller 47 controls data such as the length of the wire at the primary bending portion 4, the center angle θ1 of the coil segment, the pitch, and the shoulder angle θ2 of the coil segment, and data development for multi-axis control execution. Further, control data for bending / press and the like in the secondary bending portion 5 and data development for multi-axis control execution are performed. The second NC controller 48 performs data expansion on control data such as coil arrangement in the coil assembly unit 2. The PLC 46, the first NC controller 47, and the second NC controller 48 constitute a control unit 49 that controls the wire supply unit 3, the primary bending unit 4, the secondary bending unit 5, and the coil assembly unit 2. .

The first NC controller 47 is connected to the wire supply unit 3, the primary bending unit 4 and the secondary bending unit 5 via the optical communication cable 50 for servo link configuration. A plurality of amplification and drive circuits are connected to the optical communication cable 50 in the wire rod supply unit 3, the primary bending unit 4 and the secondary bending unit 5, and a plurality of servomotors are connected to the plurality of amplification and drive circuits. Each is connected. Signal lines from encoders mechanically connected to the plurality of servomotors are respectively connected to the plurality of amplification and drive circuits.

In the present embodiment, as described above, the primary bending portion 4 has a 5-axis control configuration, and the optical communication cable 50 includes an amplification and drive circuit of the servomotor 24 for driving in the DX direction, and a drive for driving in the DY direction. Amplification and drive circuit of servo motor 37A, amplification and drive circuit of servo motor 37B for DZ direction drive, amplification and drive circuit of servo motor 31A for DU direction drive, and amplification of servo motor 31B for DV direction drive, A drive circuit is connected.

The secondary bending unit 5 has a 6-axis control configuration, and the optical communication cable 50 includes an amplification and drive circuit for the servomotor 78 for driving in the UX direction and an amplification for the servomotor 68 for driving in the UY direction and Drive circuit, amplification and drive circuit of servo motor 82 for UZ direction drive, amplification and drive circuit of servo motor 72 for UU direction drive, amplification and drive circuit of servo motor 89 for UV direction drive, and UW direction drive The amplification and drive circuit of the servomotor 102 is connected.

The second NC controller 48 is connected to the coil assembly 2 via the optical communication cable 51 for servo link configuration. In the coil assembly unit 2, a plurality of amplification and drive circuits are connected to the optical communication cable 51, and a plurality of servomotors are respectively connected to the plurality of amplification and drive circuits. Signal lines from encoders mechanically connected to the plurality of servomotors are respectively connected to the plurality of amplification and drive circuits.

The PLC 46, the first NC controller 47 and the second NC controller 48 control the overall operation of the controller based on the steps shown in FIG.

First, among the plurality of coil segments of the coil to be manufactured, the PLC 46 performs control data for a primary bending operation on a coil segment (hereinafter referred to as a processed coil segment) to be formed and assembled next, that is, wire A series of control data defining the length, the central angle θ1, the length of each side of the transition portion 17a, the shoulder angle θ2 and the like are read from the memory and output to the first NC controller 47. Control data for the secondary bending operation, that is, a series of control data defining the movement amount of each pressing jig for forming a curved shape, the movement amount of each pressing jig for forming a step (Z bending), etc. Read out and output to the first NC controller 47. Furthermore, control data for the coil assembly operation regarding the processed coil segment, that is, the number and arrangement number of coil segments on the segment arrangement drum 105 described later in the coil assembly unit 2, index rotation amount, arm 139A of the separation preventing means 106 and A series of control data relating to the amount of rotation of 139 B, the amount of protrusion of the blade 108, the amount of movement of the pressing ring 135, etc. is read out from the memory and output to the second NC controller 48 (step S1).

Thus, the first NC controller 47 expands the received control data and executes NC control of the drive mechanism of the designated address. First, NC control of peeling of the insulating layer at both ends of the wire and cutting to a predetermined length is performed by the peeling unit 10 and the cutting unit 11 in the wire supply unit 3 (step S2). That is, the control data regarding the length of the wire (wire for the processed coil segment) 6 is expanded, and output to the drive mechanism of the peeling section 10 to drive the servomotor to be targeted to correspond to both ends of the wire. Peeling of the insulating layer is performed, control data on the length of the wire (wire for the processed coil segment) 6 is expanded, and output to the drive mechanism of the cutting unit 11 to drive the target servomotor to set the wire Cut into lengths.

Next, the first NC controller 47 performs NC control of transporting the cut wire rod (wire rod for the processed coil segment) 6 by the transport mechanism (not shown) (step S3). That is, the control data for conveyance is expanded and output to the drive mechanism of the conveyance mechanism to drive the target servomotor to cut the linear motor into a predetermined length (wire for processed coil segment) 6 Is conveyed to the primary bending unit 4. Specifically, the wire rod (wire rod for the coil segment to be treated) 6 is transported to the jigs 14A, 14B, 15A, 15B, 16A and 16B set in the initial state of the primary bending portion 4, The grooves are inserted into the grooves 14A-1, 14B-1, 15A-1, 15B-1, 16A-1 and 16B-1.

Next, the first NC controller 47 performs a primary bending process to be described later on this processed coil segment (step S4).

After completion of the primary bending, the primary bending formed body relating to the coil segment to be processed is conveyed to the secondary bending portion 5 (step S5), and the secondary bending process described later is performed on the coil segment to be processed (step S6) .

After completion of the secondary bending, the secondary bending formed body relating to the processed coil segment is transported to the coil assembly unit 2 (step S7).

Next, the second NC controller 48 performs a coil assembly process described later on the secondary bending formed body relating to the processed coil segment (step S8). As described above, based on the control information set according to the coil to be manufactured, since the processing of the coil segment to be processed is consistently performed in units of coil segments to be processed, the work efficiency is significantly increased Improve. In addition, since it becomes unnecessary to store the formed coil segments, to select a required one from the stored coil segments, etc., the control of the coil segments becomes very easy.

Next, the primary bending process in step S4 described above will be described in detail based on FIG.

First, the first NC controller 47 performs NC control to start a slight bending process of the central angle of the wire 6 by the drive mechanism 21 (step S41). That is, control data for performing a slight bending process at the central angle is developed and output to the drive mechanism 21 to drive the servomotor to be targeted to start the bending operation at the central angle of the wire 6. Specifically, the servomotors of the drive mechanism 21 operate according to the control data, and the movable bases 20A and 20B turn and the jigs 14A, 14B, 15A, 15B, 16A and 16B are light (for example, the angle θ1). The rotational movement (pivoting) to about 50%) and a slight bending of the central angle of the wire 6 is performed.

The first NC controller 47 performs NC control of coil width adjustment by the drive mechanisms 27A and 27B slightly behind the start of the operation of the drive mechanism 21 (for example, when the slider 25 moves 30 mm) (step S42). That is, the control data for adjusting the coil width is expanded and output to the drive mechanisms 27A and 27B to drive the target servomotor to linearly move the slide plates 32A and 32B. As a result, the slide plates 32A and 32B are moved by the amount of movement for obtaining the distance m according to the control data given from the home position, and the length (coil width) of each side of the transition portion is adjusted.

Next, the first NC controller 47 performs NC control in which the central angle of the wire 6 is bent to the set angle θ1 by the drive mechanism 21 (step S43). That is, control data for performing bending with the center angle set to the set angle θ1 is expanded and output to the drive mechanism 21 to drive the servomotor to be targeted and bent until the center angle of the wire 6 becomes the set angle θ1. Do the action. Specifically, the servomotor of the drive mechanism 21 is operated according to the control data, and the movable bases 20A and 20B are pivoted to rotate the jigs 14A, 14B, 15A, 15B, 16A and 16B. The center angle of the wire 6 is bent to the set angle θ1.

At the timing when the central angle is bent to the angle θ1, the first NC controller 47 performs NC control of bending the shoulder angle of the wire 6 by the drive mechanisms 28A and 28B (step S44). That is, the control data for performing the bending process of the shoulder angle is developed, and output to the drive mechanisms 28A and 28B to drive the servomotors to be processed to perform the bending operation of the shoulder angle of the wire rod 6. Specifically, the servomotors of the drive mechanisms 28A and 28B operate according to the control data, and the swing drive plates 38A and 38B move a predetermined distance in the DY + direction and the DZ + direction, respectively, and the swing plates 34A and 34B move their swing centers 44. By pivoting around the center, the jigs 16A and 16B are rotationally moved (pivoted), and the shoulder angle is bent to the angle θ2.

The central angle θ1 and / or the shoulder angle θ2 are set from the viewpoint of strongly bending in consideration of spring back. In this type of bending, when the bending force is released after bending, a so-called spring back phenomenon occurs, which slightly returns due to the elasticity on the material. The amount of return due to the spring back differs depending on the material of the wire 6, the width d2 in the flatwise direction, the width w2 in the edgewise direction, and other parameters. In the conventional method of pressing with a mold, even if the molding surface is designed in consideration of the influence of spring back in advance, the mold must be re-created if the influence of spring back is found afterward, so that molding The cost of die making has risen and is derived from the cost of forming the coil segment and, consequently, the cost of manufacturing the rotating electrical machine. In the case where the molding tool preparation is repeated several times, a significant cost increase is caused. In the present embodiment, when the influence of the spring back is found, it can be retried only by correcting the control data, so that there is no need to remake parts for molding, and it is possible to respond promptly by correcting the control data. Data that can suppress the influence of springback is acquired in advance by experiments using the above parameters to create a control table, and molding conditions that can suppress springback according to the type of the input wire 6 are automatically set You may

When the shoulder angle is completely bent to the angle θ2, the first NC controller 47 performs NC control to remove the primary bending formed body 17A which is the wire for which primary bending has been completed by the transfer mechanism 12 (see FIG. 1). (Step S45). That is, the control data for removal is developed and output to the drive mechanism of the transfer mechanism 12 to drive the target servomotor, and the primary bending formed body 17A is gripped by the pair of chuck portions by the air cylinder, The jigs 14A, 14B, 15A, 15B, 16A and 16B are removed (pulled up from the recessed groove) and transferred to the secondary bending portion 5 (step S5 in FIG. 12). Thereafter, the first NC controller 47 resets the drive mechanism of the primary bending portion 4 to prepare for the primary bending of the coil segment to be processed next.

The NC control of the secondary bending portion 5 by the first NC controller 47 and the NC control of the coil assembly portion 2 by the second NC controller 48 will be described later.

Hereinafter, the configuration and bending operation of the secondary bending portion 5 will be described in detail.

As shown in FIG. 14, the secondary bending portion 5 is curved in a convex shape corresponding to the pressing surface 53A-1 and a block-shaped pressing jig 53A having a pressing surface 53A-1 concavely curved on the lower surface. A block-shaped pressing jig 53B having a pressing surface 53B-1, a block-shaped pressing jig 54A having a pressing surface 54A-1 concavely curved on the lower surface, and a convex corresponding to the pressing surface 54A-1 on the upper surface And a block-shaped pressing jig 54B having a pressing surface 54B-1 curved in a shape of a circle. The pair of pressing jigs 53A and 53B are arranged to face each other in a crossing direction (for example, a perpendicular direction orthogonal to) intersecting with a plane (in the present embodiment, a horizontal plane) on which the primary bending molded body 17 is held. And are configured to move close to each other along this cross direction. The pair of pressing jigs 54A and 54B are also arranged to face each other in a crossing direction (for example, a perpendicular direction orthogonal to) crossing a plane (in the present embodiment, a horizontal plane) on which the primary bending molded body 17 is held. And are configured to move close to each other along this cross direction. The plane on which the primary bending molded body 17 is held is a plane in which the primary bending molded body 17 is bent at the primary bending portion 3. That is, the primary bending molded body 17 is transferred to the secondary bending portion 5 by the transfer member 12 with the posture being bent at the primary bending portion 3, and the secondary bending portion 5 is bent in this posture.

The pressing jig 53A located at the upper left in FIG. 14 has bolt insertion holes 53A-2 and 53A-3 for fixing to a support member described later, and the pressing located at the upper right in FIG. The jig 54A also has bolt insertion holes 54A-2 and 54A-3. The bolt insertion holes 53A-2 and 53A-3 are curved in a single concave shape formed by aligning the pressing jigs 53A and 54A in the horizontal position adjustment of the pressing jig 53A with respect to the pressing jig 54A. Each has an elongated hole shape in order to absorb an error in assembling the pressing surface.

The pressing jig 53B positioned at the lower left in FIG. 14 has bolt insertion holes 53B-2 and 53B-3 for fixing to a support member described later, and is positioned at the lower right in the figure. The pressing jig 54B also has bolt insertion holes 54B-2 and 54B-3. The bolt insertion holes 53B-2 and 53B-3 are curved in a convex shape formed by aligning the pressing jigs 53B and 54B in the horizontal position adjustment of the pressing jig 53B with respect to the pressing jig 54B. In order to absorb the error at the time of the assembly | attachment of the press surface which became, it becomes each long hole shape.

As described above, the primary bending molded body 17 bent into a U-shape at the primary bending portion 4 is connected by the crossover portion 17a having the chevron shape and the crossover portion 17a and extends substantially parallel to each other 1 It comprises a pair of slot inserting portions 17b and 17c. In the secondary bending portion 5, first, a crossing direction (for example, orthogonal to the orthogonal direction in which the transition portion 17a of the primary bending molded body 17 intersects with the plane (horizontal plane in the present embodiment) of the primary bending molded body 17 Bending in the direction of Specifically, the pressing jigs 53A and 54A are positioned based on the control data of the coil segment to be formed, that is, by moving the pressing jigs 53A and 54A to a state in which they are adjacent to each other. And the pressing jigs 53B and 54B are positioned on the basis of control data of the coil segment to be formed, and thus the pressing and curing surfaces 53A-1 and 54A-1 form one concave curved surface. By moving the tools 53B and 54B close to each other and adjacent to each other, the pressing surfaces 53B-1 and 54B-1 form one convex curved surface.

In this state, one or both of the pressing jigs 53A and 54A and the pressing jigs 53B and 54B are vertically moved in a plane (vertical plane) orthogonal to the plane (horizontal plane) of the primary bending molded body 17 By moving, the bridging portion 17a of the primary bending molded body 17 is pressed and molded into a curved shape. The corner portions 53A-4, 53B-4, 54A-4 and 54B-4 of the pressing jigs 53A, 53B, 54A and 54B, which come into contact with the surface of the transition portion 17a at the time of this pressing, are the insulating layers of the transition portion 17a. It is chamfered so as not to be damaged.

Since the pressing jigs 53A and 54A are not formed as an integral block but are formed as separate blocks, a bending process for forming the connecting portion 17a into a curved shape, and a crank at the top of the connecting portion 17a The secondary bending portion 5 can continuously perform the bending process of forming the stepped portion of the shape. That is, in the plane (vertical plane) orthogonal to the plane (horizontal plane) of the primary bending molded body 17, two kinds of bending processes of bending in a curved shape and formation of a step portion in a crank shape are formed Can be performed without replacing the jig. The same applies to the pressing jigs 53B and 54B. Further, by changing the moving amounts of these pressing jigs 53A, 53B, 54A and 54B, it is possible to change the control conditions in the two types of bending processing, thereby to cope with the formation of various coil segments. Can.

FIG. 15 shows the moving direction of each pressing jig of the secondary bending portion 5. As shown in the figure, the thickness in the vertical direction on the central axis side (inner side) of the pressing jig 54A is set to be larger than the thickness in the vertical direction on the central axis side (inner side) of the pressing jig 53A. The thickness in the vertical direction on the central axis side (inner side) of the pressing jig 53B is set to be larger than the thickness in the vertical direction on the central axis side (inner side) of the jig 54B. The pressing jigs 53A, 54A, 53B and 54B are separately movable in the vertical plane (UY direction, UX direction, UU direction, and UZ direction) in a vertical plane by a drive mechanism described later. By aligning the moving directions and moving speeds of the pressing jigs 53A, 54A, 53B and 54B, the pressing jigs 53A and 53B can be moved in the vertical direction (UV direction) as one pressing jig unit 55, similarly The pressing jigs 54A and 54B can be moved in the vertical direction (UW direction) as one pressing jig unit 56. The pressing jig unit 55 can also move in the horizontal direction (H direction), and therefore can move in the diagonal direction (K direction) by simultaneously performing the vertical movement and the horizontal movement. . The pressing jig unit 56 is capable of turning (pivoting) in the R direction in the vertical plane, in addition to the movement in the vertical direction. By this rotation of the pressing jig unit 56, it is possible to variably adjust the curvature of the curved surface when forming the curved shape (curved surface) in the transition portion 17a of the primary bending molded body 17, and between the slot insertion portions 17b and 17c. The curved surface can also be formed with respect to the transition portion 17a of the primary bending molded body 17 having different widths. That is, secondary bending can be performed on coil segments of various shapes. The vertical movement of the pressing jigs 53A, 53B, 54A and 54B, the horizontal movement and the diagonal movement of the pressing jig unit 55, and the turning movement of the pressing jig unit 56 are of the set movement amount. Numerical control (NC control) is performed based on data (control data). In FIG. 15, FIG. 16 and FIG. 17, the fixing portions of the pressing jigs 53A, 53B, 54A and 54B to the support members are not shown.

Next, with reference to FIG. 16, an outline of the bending operation in the secondary bending portion 5 will be described. In addition, in the same figure, only the crossover part 17a which is the process object of the primary bending forming body 17 is represented by hatching.

FIG. 16A shows a state where the pressing jigs 53A, 53B, 54A and 54B are in the initial position (home position). That is, in the same figure, the primary bending formed body 17 obtained by bending at the primary bending portion 4 is transferred by the transfer member 12, and the pair of slot insertion portions 17 b and 17 c of the primary bending formed body 17. A state in which the free end is held by the holding member 13 and then the transfer member 12 can be retracted to start bending at the secondary bending portion 5 is shown. In this home position, the pressing jigs 53A and 54A which are adjacent to each other and adjacent to each other are positioned such that the upper end faces thereof are on the same plane, and the lower ends of the pressing jigs 53B and 54B are on the same plane. It is located to be. In this state, the pressing surfaces 53A-1 and 54A-1 by the pressing jigs 53A and 54A have a step between them, and the pressing surfaces 53B-1 and 54B-1 by the pressing jigs 53B and 54B are between them. There is a step in the

As shown in FIG. 16B, from the home position state, the pressing jig unit 55 including the pressing jigs 53A and 53B is integrally moved in the left lower direction, and as a result, the pressing jig 53A and the pressing jig are pressed. While a gap g is formed between the tool 54A and the pressing surfaces 53A-1 and 54A-1 by the pressing jigs 53A and 54A, one smooth concave curved surface having no step between them is formed. The pressing surfaces 53B-1 and 54B-1 by the pressing jigs 53B and 54B also constitute a smooth single convex curved surface without any step between them.

From this state, as shown in FIG. 16 (c), first, the pair of pressing jigs 53B and 54B are lifted and brought into contact with the lower surface of the transition portion 17a, and in this state, the pair of pressing jigs 53A and The pressing operation is started by lowering 54A. That is, a concave curved surface by the pressing surfaces 53A-1 and 54A-1 of the pair of pressing jigs 53A and 54A and a convex shape by the pressing surfaces 53B-1 and 54B-1 of the pair of pressing jigs 53B and 54B. The pressing operation is performed with the connecting portion 17a interposed between the connecting portion 17a and the curved surface, and the connecting portion 17a is bent in the direction perpendicular to the horizontal plane. When the pressing operation has progressed to a certain extent, in other words, when there is no possibility that the primary bending molded body 17 is displaced, the holding (chucking by the air cylinder) by the holding member 13 is released. The moving process of the pressing jig in this pressing operation is not limited to the above-described example, and various moving processes can be made within the range in which the primary bending molded body 17 does not shift. By the completion of the pressing operation, the bending process which is the forming of the curved shape of the transition portion 17a is completed.

After the formation of the curved shape of the crossover portion 17a is completed, the pressing surfaces 53A-1 and 54A-1 of the pressing jigs 53A and 54A and the pressing surfaces 53B-1 and 54B-1 of the pressing jigs 53B and 54B are the crossover portions. While holding 17a, as shown in FIG. 16 (d), the upper end surfaces of the pressing jigs 53A and 54A become the same surface, and the lower end surfaces of the pressing jigs 53B and 54B become the same surface. Thus, the pressing jig unit 55 (pressing jigs 53A and 53B) is moved in the upper right direction. Thus, a crank-shaped step portion 57 is formed at the top of the transition portion 17a. That is, the gap g due to the movement of the pressing jig unit 55 in the lower left direction shown in FIG. 22B is formed for forming the curved shape on the connecting portion 17a and forming the stepped portion in the crank shape. It is

It is possible to simultaneously perform the forming of the curved shape to the transition portion 17a and the formation of the step portion of the crank shape in one pressing operation by using the molding die in which the shape of the pressing surface is fixed as in the prior art. . However, according to the forming method in which the forming die has the desired curved shape and step shape in advance as in the prior art, it has been necessary to replace the forming die each time when performing bending of various shapes. In addition, since an excessive bending process is performed by the forming die and both sides of the wire, in some cases, the entire peripheral surface receive a pressing force, there is a possibility that the insulating layer of the wire may be damaged. That is, although it was attempted to increase the bending accuracy, the edge of the forming surface was sharpened, but the stress was concentrated on this and the insulating layer was easily damaged. Moreover, in the method of pressing with a mold, it is not known whether the insulating layer will be damaged unless the pressure is actually pressed, and if there is a problem, it is necessary to redo the production of the mold, resulting in cost increase. . On the other hand, in the present embodiment, each bending process (forming process) is intentionally simplified by separately performing a plurality of bending processes (forming) of forming a curved shape and forming a crank-shaped step portion. And by moving the pressing jig. Therefore, it is possible to solve the above-mentioned problems caused by using the forming die, and the transition between the forming process of the curved shape and the forming process of the step portion of the crank shape is also only the change of the moving amount of the pressing jig. The molding time is almost the same as that of the prior art in which molding is performed in one step using a molding die. Furthermore, in the present embodiment, in the bending process of forming a curved shape, since the transition portion is sandwiched and pressed between smooth curved surfaces, the damage of the insulating layer of the wire does not occur. Further, in the formation of the crank-shaped stepped portion, only the positions of the pair of pressing jigs sandwiching the crossover portion are shifted, and the configuration is not such that the molding surface having the stepped shape is pressed. There is no damage.

Next, the adjustment operation of the curvature of the curved shape in the bending process of the curved shape forming will be described with reference to FIG. FIG. 17A shows an initial state before the curvature adjustment operation is performed. This state corresponds to the state shown in FIG. 17C, and the radius of curvature is R1. From this state, when the pressing jig unit 56 on the right side in the figure is rotated about the curvature center C described later by an angle θ, as shown in FIG. 17B, the curvature radius is R1 to R2 (R1 <R1 < R2), and the curvature (1 / R2) decreases. That is, the curvature in the curved shape of the transition portion 17a can be changed by the rotation of the pressing jig unit 56, and various coil segments having different curvatures of the curved shape of the transition portion 17a can be bent. This means that even when the width between the slot insertion portions 17b and 17c of the primary bending molded body 17 is different, the curvature can be adjusted to perform corresponding bending.

Next, the configuration including the drive mechanism of the secondary bending portion 5 will be described in detail with reference to FIG. 18 to FIG.

As shown in FIG. 18, the secondary bending portion 5 is disposed in parallel with a vertical plane (a plane orthogonal to the horizontal plane on which the primary bending molded body 17 is held), and fixed with an opening 58a at the center. A base 58, a movable base 59 provided movably in the left-right direction parallel to the fixed base 58, and a drive mechanism 60A fixed to the movable base 59 and moving the pressing jig 53A in the vertical direction (UY direction) A drive mechanism 60B fixed to the movable base 59 and moving the pressing jig 53B in the vertical direction (UU direction), and a drive mechanism fixed to the fixed base 58 and moving the movable base 59 in the horizontal direction (UV direction) 61, and a rotation base 62 connected to the fixed base 58 and rotatably provided around the center of curvature C in a vertical plane, and fixed to the rotation base 62 to move the pressing jig 54A up and down Drive mechanism 63A for moving in the direction (UX direction), drive mechanism 63B fixed to the rotation base 62 and moving the pressing jig 54B in the vertical direction (UZ direction), and connected to the rotation base 62, A drive mechanism 64 is provided to rotate the center of curvature C by driving the rotation base 62 in the vertical direction (UW direction). As shown in FIG. 25, the fixed base 58 is vertically supported by two L-shaped brackets 94 fixed on both sides in the longitudinal direction (left and right direction).

The drive mechanism 60A includes a ball screw portion 65 having a UY direction rotation axis parallel to the vertical direction, a nut portion 66 screwed to the ball screw portion 65 and slidable in the UY direction, and a ball screw portion 65. Instead, a slider 67 slidably provided in the UY direction along the rotation axis and a servomotor 68 for rotationally driving the ball screw portion 65 are provided.

The drive mechanism 60B includes a ball screw portion 69 having a UU-direction rotation axis parallel to the vertical direction, a nut portion 70 screwed on the ball screw portion 69 and slidable in the UU direction, and a ball screw portion 69. Instead, a slider 71 slidably provided in the UU direction along the rotation axis, and a servomotor 72 for rotationally driving the ball screw portion 69 are provided.

A moving plate 73 which is a member for supporting the pressing jig is fixed to the nut portion 66 of the driving mechanism 60A and the slider 71 of the driving mechanism 60B, and a plurality of pressing jigs 53A are provided at the lower right end of the moving plate 73. It is fixed by a bolt screw. Therefore, only the pressing jig 53A can be moved in the UY direction by the operation of the servomotor 68 of the drive mechanism 60A. In addition, a moving plate 74 which is a member for supporting the pressing jig is fixed to the slider 67 of the drive mechanism 60A and the nut portion 70 of the drive mechanism 60B. The tool 53B is fixed by a plurality of bolt screws. Therefore, only the pressing jig 53B can be moved in the UU direction by the operation of the servomotor 72 of the drive mechanism 60B. The moving plates 73 and 74 are supported across the drive mechanisms 60A and 60B in order to obtain rigidity and stability for securing and maintaining pressing accuracy by the pressing jigs 53A and 53B.

The drive mechanism 63A includes a ball screw portion 75 having a rotation axis in the UX direction parallel to the vertical direction, a nut portion 76 screwed to the ball screw portion 75 and slidable in the UX direction, and a ball screw portion 75. Instead, a slider 77 slidably provided in the UX direction along the rotation axis and a servomotor 78 for rotationally driving the ball screw portion 75 are provided.

The drive mechanism 63B includes a ball screw portion 79 having a UZ direction rotation axis parallel to the vertical direction, a nut portion 80 screwed in the ball screw portion 79 and slidable in the UZ direction, and a ball screw portion 79. Instead, a slider 81 slidably provided in the UZ direction along the rotation axis and a servomotor 82 for rotationally driving the ball screw portion 79 are provided.

A moving plate 83, which is a member for supporting the pressing jig, is fixed to the nut portion 76 of the driving mechanism 63A and the slider 81 of the driving mechanism 63B, and a plurality of pressing jigs 54A are provided at the left lower end of the moving plate 83. It is fixed by a bolt screw. Therefore, only the pressing jig 54A can be moved in the UX direction by the operation of the servomotor 78 of the drive mechanism 63A. Further, a moving plate 84 which is a member for supporting the pressing jig is fixed to the slider 77 of the driving mechanism 63A and the nut portion 80 of the driving mechanism 63B, and the pressing jig 54B is fixed to the upper left end of the moving plate 84. It is fixed by multiple bolt screws. Therefore, only the pressing jig 54B can be moved in the UZ direction by the operation of the servomotor 82 of the drive mechanism 63B. The moving plates 83 and 84 are supported across the drive mechanisms 63A and 63B in order to obtain rigidity and stability for securing and maintaining pressing accuracy by the pressing jigs 54A and 54B.

Next, with reference to FIGS. 18 to 20, the structure in which the movable base 59 supporting the drive mechanisms 60A and 60B moves laterally and the drive mechanism 61 for moving the movable base 59 will be described. FIG. 19 shows the disassembled configuration of one side portion (left half when viewed from the front) of the secondary bending portion 5 and the periphery of the drive mechanism 61, and FIG. 20 shows the operation of this portion.

As shown in FIGS. 18 and 19, the drive mechanism 61 fixed to the fixed base 58 has a ball screw portion 85 having a rotational axis in the UV direction parallel to the vertical direction, and is screwed with the ball screw portion 85. It comprises nut portions 86 and 87 slidable in directions, a slide plate 88 fixed to the nut portions 86 and 87 and slidable in the UV direction, and a servomotor 89 for rotationally driving the ball screw portion 85. A pair of rail members 90 extending in the left-right direction are fixed to the fixed base 58 in parallel in the upper and lower two rows. Two pairs of sliding members 91 are fixed to the back surface of the movable base 59. Each pair of sliding members 91 is slidably engaged with the rail members 90 along the respective rail members 90. Thus, the movable base 59 is supported so as to be movable in the left-right direction (horizontal direction) orthogonal to the UV direction (see FIG. 18).

As shown in FIGS. 19 and 20, the movable base 59 is provided with a cam follower 92 projecting from the surface thereof, and an engagement groove 93 in which the cam follower 92 is engaged and slides on the back surface of the slide plate 88. Are formed inclined with respect to the UV direction. In the state shown in FIG. 16 (c), the cam follower 92 engaged with the engagement groove 93 is in the position shown in FIG. 20 (a). When the servomotor 89 of the drive mechanism 61 operates and the slide plate 88 ascends in the UV + direction, the slide plate 88 ascends and the engagement groove 93 ascends. Thereby, the cam follower 92 sliding in the engagement groove 93 is guided to the right in the figure as shown in FIG. 20B, and the movable base 59 to which the cam follower 92 is fixed is It moves to the right by a dimension S shown in FIG. If the servomotor 89 is reversely rotated, the movable base 59 moves in the reverse direction. By changing the inclination angle and / or the length of the engagement groove 93, the amount of movement of the movable base 59 in the left and right direction can be changed. By changing the amount of movement of the movable base 59 in the left-right direction, it is possible to change the curvature of the crank shape or the step shape formed in the connecting portion 17a or the curved shape.

As described above, the pressing jig unit 55 including the pressing jigs 53A and 53B can be moved in the vertical direction by the drive mechanisms 60A and 60B. Therefore, the movement in the lateral direction by the drive mechanism 61 and the vertical movement by the drive mechanisms 60A and 60B By simultaneously performing the movement of the direction in combination, the oblique movement of the pressing jig unit 55 becomes possible. For example, from the home position state shown in FIG. 16A by moving moving plates 73 and 74 downward by driving mechanisms 60A and 60B simultaneously with moving movable base 59 leftward by driving mechanism 61. In the state shown in FIG. 16 (b), oblique movement is possible. Further, from the state shown in FIG. 16C, the movable plates 73 and 74 are moved upward by the drive mechanisms 60A and 60B simultaneously with the movement of the movable base 59 in the right direction by the drive mechanism 61. In the state shown in (d), oblique movement is possible.

Next, with reference to FIGS. 21 and 22, a configuration in which the pivot base 62 supporting the drive mechanisms 63A and 63B pivots and a drive mechanism 64 in which the pivot base 62 is pivoted will be described. FIG. 21 shows the disassembled configuration of one side portion (right half when viewed from the front) of the secondary bending portion 5 and the periphery of the drive mechanism 64, and FIG. 22 shows the operation of this portion.

As shown in these figures, the fixed base 58 has a common center of curvature C and a pair of arc-shaped rail members 95 and 96 having different curvatures are fixed apart from each other in the left-right direction. A pair of sliding members 97 and one sliding member 98 are fixed to the back of the moving base 62. A pair of sliding members 97 are slidably engaged with the rail members 95 along the rail members 95, and one sliding member 98 is slidably movable along the rail members 96. Is engaged. The drive mechanism 64 is fixed to a ball screw portion 99 having a UW direction rotation axis parallel to the vertical direction, a nut portion 104 screwed to the ball screw portion 99 and slidable in the UW direction, and a nut portion 104 The engaging member 101 and the servomotor 102 for rotationally driving the ball screw portion 99 are provided. The rotation base 62 is provided with a cam follower 103 projecting from the surface thereof, and the back surface of the engagement member 101 is provided with an engagement groove 101a (see FIG. 21) with which the cam follower 103 is engaged.

When the servomotor 102 of the drive mechanism 64 operates and the engaging member 101 moves in the UW-direction, the cam follower 103 engaged with the engaging groove 101a moves, so the sliding members 97 and 98 are rails. Sliding along the members 95 and 96, the pivot base 62 pivots counterclockwise around the center of curvature C. That is, the turning base 62 in the state (central position) shown in FIG. 22 (a) turns to the state shown in FIG. 22 (b). Since the pressing jigs 54A and 54B are fixed to the pivoting member 62, the pressing jig unit 56 in which these are integrated is pivoted. In this case, the curvature at the time of forming the curved shape with respect to the transition portion 17a by the pressing jigs 53A, 53B, 54A and 54B becomes large. Conversely, when the pivoting base 62 is pivoted clockwise from the central position shown in FIG. 22A, the curvature at the time of forming the curved shape can be reduced. The center of curvature C, which is the center of rotation of the rotation base 62 stably guided by the pair of rail members 95 and 96, is in the vicinity of the left end of the pressing jigs 54A and 54B. The curvature at the time of forming a curved shape can be changed with high accuracy.

Next, the electrical configuration of the secondary bending portion 5 will be described. In the present embodiment, as described above, the secondary bending unit 5 has a 6-axis control configuration, and the optical communication cable 50 includes an amplification and drive circuit for the servomotor 78 for driving in the UX direction, for driving in the UY direction. Amplification and drive circuit of servo motor 68, amplification and drive circuit of servo motor 82 for UZ direction drive, amplification and drive circuit of servo motor 72 for UU direction drive, amplification and drive circuit of servo motor 89 for UV direction drive The circuit and the amplification and drive circuit of the servomotor 102 for UW direction drive are connected.

The PLC 46 and the first NC controller 47 form a curved shape and crank the primary bending formed body 17 related to the processed coil segment based on the steps shown in the flowchart of FIG. 23 corresponding to the process of step S6 of FIG. Control the secondary bending operation to form the step portion of The secondary bending operation will be described in detail below using this flowchart. In the following description, the secondary bending is performed on the primary bending molded body 17 in which the coil width is small, that is, the length of each side of the crossover portion is small.

The first NC controller 47 develops control data concerning the received coil assembly operation, and executes NC control of the drive mechanism of the designated address. First, NC control is performed on the placement and movement of the pressing jigs 53A, 53B, 54A and 54B according to the dimensions (shapes) of the primary bending molded body 17 (step S61). That is, the control data regarding the movement amount of the pressing jig is expanded, and the secondary curved surfaces of the concave curved surfaces by the pressing jigs 53A and 54A and the convex curved surfaces by the pressing jigs 53B and 54B have a predetermined curvature. The servomotor to be output is outputted to the drive mechanisms 60A, 60B, 63A and 63B of the bending portion 5, and the pressing jig is moved. FIG. 16 (b) shows this state.

Next, the first NC controller 47 performs NC control to execute a light pressing process (light pressing process) to lightly press the transition portion 17a of the primary bending molded body 17 (step S62). That is, the control data for the pressing process is expanded and output to the drive mechanism of the secondary bending unit 5 to drive the target servomotor to perform the light pressing process, and the primary bending formed body 17 is not displaced. Let's do it.

Next, the first NC controller 47 performs NC control to release the holding of the primary bending formed body 17 by the holding member 13 (step S63). That is, the control data for releasing the primary bending formed body 17 from the holding member 13 is expanded and output to the drive mechanism of the holding member 13 and the air cylinder is driven to release the gripping of the slot insertion portions 17b and 17c by the chucks. .

Next, the first NC controller 47 performs NC control of bending for bending the transition portion 17a into a curved shape (step S64). That is, control data for pressing is developed and output to the drive mechanisms 60A, 60B, 63A and 63B, and the servomotors to be targeted are driven to perform pressing processing.

In this type of bending (pressing process), when the pressing force is released after bending, there is a possibility that a so-called spring back phenomenon may occur due to the elasticity of the material to return slightly. The amount of return due to the spring back varies depending on the material of the wire 6 and the parameters such as the curvature of the curved shape. In the conventional method in which molding is performed by pressing with a molding die, even if the molding surface is designed in consideration of the influence of spring back in advance, if the influence of spring back is found afterward, the mold must be re-created. In addition, the forming cost of the forming mold is increased, and the forming cost of the coil segment and the manufacturing cost of the rotary electric machine are increased. When the molding die preparation is repeated several times, the cost is significantly increased. In the present embodiment, when the influence of the spring back is found, for example, the pressing time can be extended, the moving amount of the pressing jig in the pressing direction can be increased, and correction can be made only by correcting the control data. The control table may be created by acquiring data which can suppress the influence of the spring back in advance by using the above-mentioned parameters to create a control table, or a spring according to the type of the input wire 6 or the shape of the primary bending formed body 17 A molding condition that can suppress the back may be set automatically.

Next, the first NC controller 47 performs NC control in which the pressing jig unit 55 (pressing jigs 53A and 53B) is moved obliquely by the drive mechanism 61 to form a crank-shaped stepped portion (step S65). That is, the control data for forming the stepped portion is expanded and output to the drive mechanism 61, and the control data is output to the drive mechanisms 60A and 60B while driving the servomotor 89 to move the movable base 59 in the right direction. And the servomotors 68 and 72 to move the pressing jigs 53A and 53B upward in synchronization with each other, thereby moving the pressing jig unit 55 including the pressing jigs 53A and 53B obliquely upward to the right Let

After forming the step portion, the first NC controller 47 performs NC control to partially release the pressed state (step S66). That is, control data for moving the left pressing jigs 53A and 53B is expanded and output to the drive mechanisms 60A and 60B, and the servomotors 68 and 72 are driven to separate the pressing jigs 53A and 53B from the pressed position. To control.

At a timing when the left pressing jigs 53A and 53B move away from the pressing position, the first NC controller 47 grips the secondary bending formed body 17 which is the wire for which the secondary bending is finished, and transfers it to the coil assembly part 2. NC control for preparation is performed (step S67). That is, the control data for transfer is developed and output to the drive mechanism of the loader (not shown), and the air cylinder is driven to grip the secondary bending molded body 17 with a pair of chucks.

Thereafter, the first NC controller 47 resets the drive mechanism of the secondary bending portion 5 to prepare for the secondary bending of the next coil segment (primary bending formed body).

As described above, in the present embodiment, the bending area of the primary bending portion 4 and the bending area of the secondary bending portion 5 do not overlap in one plane, and exist separately. That is, the movement and configuration of bending in the primary bending portion 4 and the secondary bending portion 5 are avoided by using the three-dimensional shape mold as in the prior art and removing the idea of press forming at one time and daringly setting it as separate steps. To simplify processing by numerical control.

In the above-described secondary bending operation, although a crank-shaped step is formed at the top of the transition portion 17a of the primary bending molded body 17, 1 of the primary bending molded body 17 for lane change. As long as the slot insertion portions of the pair are shifted in the radial direction of the slots, they are not limited to the steps, and may be smooth or may have any shape.

Hereinafter, the configuration and operation of the coil assembly unit 2 will be described in detail.

As shown in FIGS. 25, 26 and 29, the coil assembly unit 2 comprises segment transport means 110 for transporting the coil segments 17S sequentially, and a plurality of coil segments as shown in FIGS. 24A to 24F and 29. A segment arrangement drum 105 (corresponding to the segment arrangement body of the present invention) in which a plurality of segment holding parts 109 capable of respectively inserting 17S radially from the outside are arranged annularly along the circumferential direction, and a plurality of coil segments A guide member 112 (corresponding to the guide means of the present invention) having a one-stage structure for guiding and inserting the 17S into the plurality of segment holding portions 109 is provided. The segment arrangement drum 105 is configured to rotate around a central axis C (rotational axis 121) by a predetermined angle by an index rotational drive mechanism (not shown). The guide member 112 is disposed above the segment placement drum 105, and one of the pair of slot insertion portions 17b and 17c of each coil segment 17S each time the segment placement drum 105 rotates a first predetermined angle. Slot insertion part (front leg) 17b is guided and inserted into one segment holding part 109, and when it is rotated by a second predetermined angle from the insertion of the one slot insertion part 17b, the other slot insertion part (rear leg ) 17c is configured to be guided and inserted into another one of the segment holding portions 109.

As shown in FIGS. 24A to 24F and 29, the coil assembly unit 2 separates the plurality of coil segments inserted in the plurality of segment holding portions 109 of the segment arrangement drum 105 from the plurality of segment holding portions 109. It has the detachment prevention means 106 which supports so that it does not carry out. The detachment preventing means 106 is in contact with the circumferential surface of the segment placement drum 105, and is made of a rubber belt 107 as a flexible contact member that rotates (follows rotation) with the rotation of the segment placement drum 105. Corresponding to the belt body of The belt 107 is formed in a narrow width of about 3 cm, and is looped so as to cover a part of the segment arrangement drum 105 in the circumferential direction at a plurality of locations (here two locations) in the axial direction of the segment arrangement drum 105 Is located in However, the belt 107 is not disposed above the segment disposition drum 105 where the coil segment 17S is guided. The details of the configuration of the detachment prevention means 106 will be described later.

The segment arrangement drum 105 is arranged such that the central axis C of its rotation is horizontal, so that the plurality of coil segment holding parts 109 are also horizontal. In this embodiment, the segment arrangement drum 105 is rotatably supported in the counterclockwise direction in FIG. 24A. In other words, in the segment arrangement drum 105, the central axis C thereof is substantially parallel to the axial direction (insertion direction to the slot) of the coil segment 17S in a state where bending at the secondary bending portion 5 is completed. It is arranged horizontally.

Inside the segment arrangement drum 105, a plurality of blades 108, which are axially extending partition walls, are annularly arranged along the circumferential direction of the segment arrangement drum 105 and extend radially from the central axis C. A plurality of segment holding parts 109 are respectively formed between the plurality of blades 108. The radial heights of the plurality of blades 108 are variable as they slide in the radial direction. The radial height of the plurality of blades 108, that is, the amount of radially outward projection of the segment arrangement drum 105 is configured to be adjusted simultaneously for all the blades 108. The adjustment structure will be described later. The belt 107 of the detachment prevention means 106 is substantially in contact with the blade 108.

The processed coil segment 17S whose bending is completed in the secondary bending portion 5 is conveyed by the segment conveying means 110 in parallel from the secondary bending portion 5 and guided and inserted into the segment holding portion 109 of the segment arrangement drum 105 . As shown in FIG. 25, the segment transport means 110 is provided with a chuck portion 111 for gripping one of the pair of slot insertion portions 17b and 17c of the coil segment 17S, the slot insertion portion (rear leg) 17c. The entire segment transport means 110 is movable in the vertical direction (Z (-) (+) direction) and in the horizontal direction (X (-) (+) direction). The X (−) (+) direction is a direction in which the segment conveyance means 110 moves back and forth between the secondary bending portion 5 and the segment arrangement drum 105. In addition, the chuck portion 111 is rotatable in the R direction in the vertical plane, and is configured to be able to change its posture in a state in which one slot insertion portion (rear leg) 17c of the coil segment 17S is gripped. There is.

FIG. 25 shows a state in which the processed coil segment 17S is gripped and moved by the segment conveying means 110 before bending at the secondary bending portion 5 is completed and released from the pressing jig. The chuck portion 111 of the segment conveyance means 110 grips the other slot insertion portion (rear leg) 17c which is the rear side when moving toward the coil assembly portion side (segment placement drum 105 side) of the coil segment 17S. There is. Before the coil segment 17S is transported to the segment placement drum 105, the chuck portion 111 of the segment transport means 110 pivots upward (R (+) direction) and the front slot insertion portion (front leg) 17b is inclined. The posture of the coil segment 17S is inclined to be downward.

The configuration of the segment conveyance means 110 will be described in more detail. As shown in FIG. 25, the segment conveyance means 110 has a horizontal direction (X (-) (+) direction) and a vertical direction (Z (Z ( -) The base 157 provided movably in the (+) direction, the chuck portion 111 rotatably attached to the base 157, and the chuck portion 111 are turned in the R (-) (+) direction And a drive mechanism 158. The driving mechanism 158 has a ball screw portion 159 having a rotation axis parallel to the X (-) (+) direction, and a nut portion screwed to the ball screw portion 159 and slidable in the X (-) (+) direction. 160, a servomotor 161 for rotationally driving the ball screw portion 159, and a slider 162 fixed to the nut portion 160 and moving in the X (-) (+) direction with the rotation of the ball screw portion 159 There is.

The slider 162 has a rectangular shape extending in the vertical direction, and a drive claw 164 is fixed to the back surface of the lower end portion thereof via a bracket 163. Further, as shown in FIG. 26, an arc-shaped rail 165 is fixed to the back surface side of the base 157, and the chuck portion 111 is supported by a pivoting base 166 which is engaged with the rail 165 and pivots. The swing base 166 is provided with an air cylinder 167 that opens and closes the chuck portion 111. As shown in FIG. 25, a cam follower 168 is provided on the surface side of the turning base 166, and a concave groove 164 a engaged with the cam follower 168 is formed in the drive claw 164. When the servo motor 161 of the drive mechanism 158 operates and the slider 162 moves in the X (-) direction, the chuck portion 111 rotates in the R (-) direction, and when the slider 162 moves in the X (+) direction, the chuck The part 111 rotates in the R (+) direction. Therefore, by controlling the operation of the servomotor 161, the inclination of the coil segment 17S can be changed.

As shown in FIG. 24A, a guide surface 112c is provided along the circumferential surface of the segment arrangement drum 105 above the segment arrangement drum 105 to guide the coil segment 17S to a predetermined segment holding portion 109 of the segment arrangement drum 105. The guide member 112 is supported by a frame (not shown). As shown in FIG. 29, the guide member 112 extends in the axial direction of the segment arrangement drum 105, and is arranged at a distance from the circumferential surface of the segment arrangement drum 105. As shown in FIG. 27, the guide member 112 is provided with a plurality (three in this example) of narrow guide pieces 112a and a bracket 112b for supporting the guide pieces 112a apart from each other. The bracket 112b is provided along the axial direction of the segment arrangement drum 105, and the guide piece 112a extends in the direction orthogonal to the bracket 112b. The bracket 112 b is fixed to a frame (not shown) as described above.

The front leg 17b of the coil segment 17S is gripped by the chuck portion 111 of the segment conveying means 110, and the lower side of the guide member 112 (between the guide member 112 and the segment arrangement drum 105) as shown in FIG. Then, the leg 17c is conveyed so as to pass the upper side of the guide member 112 (the side opposite to the segment placement drum 105 of the guide member 112). As shown in FIG. 24A, the segment transport means 110 is configured to be lowered when the front leg 17b of the coil segment 17S reaches above the segment holding portion 109a which is a reference point. The reference point in the present embodiment is set in the segment holding portion 109a between the blade 108 located at the upper center of the segment placement drum 105 and the blade 108 adjacent to the downstream side of the rotation direction of the segment placement drum 105. The reference point is not limited to this. When it is detected by the detection sensor 170 disposed on the lower surface of the guide member 112 that the segment transport means 110 is lowered and the front leg 17b of the coil segment 17S is inserted into the segment holding portion 109a, The chuck portion 111 releases the coil segment 17S. Thereby, the rear leg 17c of the coil segment 17S is mounted on the guide member 112.

When it is detected that the front leg 17b of the coil segment 17S has been inserted into the segment holding portion 109a, the segment placement drum 105 is set to a first predetermined angle for one slot, ie, a first portion of the segment holding portion 109. It is controlled to rotate counterclockwise in the figure by a predetermined angle of 1 (index rotation). Since the front leg 17b of the coil segment 17S is accommodated and restrained in the segment holding portion 109, when the segment placement drum 105 rotates, the rear leg 17c of the coil segment 17S slides on the guide surface 112c and moves. When the segment arrangement drum 105 is rotated by one slot, the segment holding portion 109b adjacent to the upstream side in the rotational direction of the segment holding portion 109a which is the first reference point becomes the reference point of the coil segment 17S to be arranged next. In order to smoothly insert the front leg 17b into the segment holding portion 109 at the reference point, the upstream side in the rotational direction of the segment arrangement drum 105 of each blade 108 is chamfered to form a tapered surface 108b. In the present embodiment, since the number of slots per rotation is 36, the angle for one slot of the segment arrangement drum 105, that is, the first predetermined angle is 10 degrees.

Next, the operation of sequentially inserting and arranging the plurality of coil segments 17S in the plurality of segment holding portions 109 on the circumferential surface of the segment arrangement drum 105 will be described. In the drawing, the coil segment 17S is displayed only on the end faces of its front leg and rear leg, and the front leg is distinguished by white outline, and the rear leg is distinguished by ×.

FIG. 24B shows a state in which the front legs 17b of the three coil segments 17S are respectively inserted into the segment holding portion 109 of the segment arrangement drum 105, and the respective rear legs 17c are placed on the guide surface 112c. In FIG. 24B, reference numerals 17b-1, 17b-2 and 17b-3 respectively indicate the front legs of the first to third coil segments 17S, and 17c-1, 17c-2 and 17c-3 respectively indicate the first to third ones. The rear leg of the coil segment 17S is shown.

FIG. 24C shows a state in which the rear leg 17c-1 of the first coil segment 17S drops away from the guide member 112. The coil segment 17S whose rear leg 17c-1 is separated from the guide member 112 is pivoted by gravity with the front leg 17b-1 already inserted in the segment holding portion 109 of the segment arrangement drum 105 as a fulcrum, and the rear leg 17c- 1 is inserted into a predetermined segment holding unit 109 by its own weight without control. In the present embodiment, the eighth segment holding portion 109 on the upstream side in the rotational direction of the segment placement drum 105 counted from the segment holding portion 109 into which the front leg 17b-1 is inserted is the rear leg 17c-1 according to the width of the coil segment 17S. Is inserted. In other words, when the segment arrangement drum 105 is rotated by a second predetermined angle of eight slots, that is, the second predetermined angle of eight segment holding portions 109, the rear leg 17c-1 is rotated. It is inserted into the segment holding unit 109. The relative angle of the front leg inserted in the segment holding portion 109 with respect to the circumferential surface of the segment placement drum 105 decreases as the index rotation progresses, that is, the posture is parallel to the circumferential surface. To go. In the present embodiment, since the number of slots per round is 36, the angle for eight slots of the segment arrangement drum 105, that is, the second predetermined angle is 80 degrees. However, this second predetermined angle differs depending on the coil width of the coil segment.

In FIG. 24D, the back legs of the first to third coil segments 17S are guided and inserted into the segment holding portion to be placed on the front legs of the eighth to tenth coil segments 17S, and the back legs of the fourth coil segment 17S. Shows a state of being separated from the guide member 112. As apparent from FIG. 24D, for example, the rear leg 17c-1 of the first coil segment 17S is inserted and arranged on the front leg 17b-8 of the eighth coil segment 17S. This is because, as shown in FIG. 24A, a so-called lane change is possible due to the rear leg 17c-1 being shifted outward in the radial direction of the segment arrangement drum 105 by the step 17a-1 formed in the crossover portion 17a of the coil segment It is because. In other words, the front leg 17b-1 of the first coil segment 17S is disposed in the first layer, and the rear leg 17c-1 is disposed in the second layer.

When the same operation is performed and the first round of insertion and placement of the rear legs of all the coil segments 17S is completed, placement of the two layers of the coil segments 17S is completed, as shown in FIG. 24E. When the arrangement of the first turn is completed for all the coil segments 17S, as shown in FIG. 24F, the insertion and arrangement of the first coil segment 17S of the second turn starts. Note that each blade 108 protrudes radially outward of the segment placement drum 105 before the second round of insertion and placement starts. The amount of projection of the blade 108 is set to be greater than the total thickness of the coil segments already inserted. The tolerance (height Yt) of the protrusion amount of the blade 108 to the total thickness of the coil segment is a range in which the front leg and the rear leg of the coil segment 17S can be stably inserted and arranged and the new insertion is not inhibited, for example , 4 mm.

In a state where the projecting operation of the blade 108 is completed, the first front leg 17b-1 of the coil segment 17S of the second round is inserted into the segment holding portion 109a of the reference point, and the rear leg 17c-1 is mounted on the guide member 112 . Thereafter, the coil segments 17S are sequentially inserted in the same manner as in the first round, and when the segment arrangement drum 105 makes one rotation, the insertion and arrangement in the second round are completed, and the arranged coil segments 17S become four layers. If the amount of protrusion corresponding to the thickness of the target layer is set from the beginning to the blade 108, the segment holding portion becomes deep and smooth insertion operation is impeded. Therefore, as the stepwise protrusion operation corresponding to the layer thickness as described above There is. As the number of layers increases, the diameter of the circumferential surface of the segment placement drum 105 changes, so that the contact pressure of the belt 107 with the blade 108 is kept constant, as described later, in accordance with the protrusion operation of the blade 108. An adjustment is made.

In the embodiment described above, as shown in FIG. 28, the coil segments supplied to the coil assembly unit 2 are arranged such that the coil segments 17S having basically the same shape are sequentially arranged in the same pattern. That is, when 10 coil segments are simply arranged and developed, the rear legs of the first to third coil segments are disposed on the front legs of the eighth to tenth coil segments, respectively.

As described above, according to the present embodiment, the coil segment 17S which has been bent into a predetermined shape is placed above the segment arrangement drum 105 which is horizontally disposed in the state of being laid horizontally at the time of bending. The coil segment 17S is continuously inserted into the segment holding portion while being conveyed and rotating the segment disposition drum 105 by a predetermined angle. As described above, since the segment arrangement drum 105 is arranged horizontally and the coil segment 17S is guided from above, if only the front leg of the coil segment 17S is inserted into the predetermined segment holding portion of the segment arrangement drum 105, The rear legs are inserted automatically under their own weight. For this reason, automation is easy compared with the past, and a coil can be assembled quickly and efficiently.

Next, the specific configuration of the coil assembly unit 2 of the present embodiment will be described in detail based on FIGS. 25 to 27 and 29 to 33.

As shown in FIGS. 29 and 30, the coil assembly 2 is disposed on the base 116 and on the base 116 so that the rotation axis 121, which is the central axis C of its rotation, is horizontal, and is rotatably supported. Segment placement drum 105, separation prevention means 106 having a belt 107, servomotor 117 which is a drive source for driving the segment placement drum 105 to rotate, a blade adjustment mechanism 118 for changing the projection amount of the blade 108, segment placement An extruding mechanism for extruding an assembled coil consisting of a predetermined number (36 in the above embodiment) of coil segments inserted and held in the annularly arranged segment holding portion 109 of the drum 105 in the axial direction of the segment arrangement drum 105 119 and the opposite side of the pushing mechanism 119 with the segment arrangement drum 105 interposed therebetween. It has the work support stand 120 placed, the segment conveyance means 110 mentioned above, and the guide member 112 of 1 step | paragraph structure.

The segment arrangement drum 105 is rotatably supported around its rotation axis 121. A disc-like bearing 122 for supporting the rotation shaft 121 is disposed on the side opposite to the assembly coil extruding direction (P (+) direction) of the segment arrangement drum 105. The diameter gear 123 is coaxially fixed. A small diameter gear (not shown) fixed to the rotational shaft of the servomotor 117 is engaged with the large diameter gear 123. Therefore, when the servomotor 117 rotates, the segment arrangement drum 105 is rotationally driven through the rotation shaft, the small diameter gear, and the large diameter gear 123. The speed reduction structure based on the engagement of the small diameter gear and the large diameter gear 123 can increase the accuracy of the index rotation of the segment arrangement drum 105 by the servomotor 117.

The bearing 122 is supported by a receiving portion 124 whose bottom is fixed to the base 116, whereby the segment arrangement drum 105 is supported in a cantilever manner. However, since the portion where the coil segment 17S of the segment arrangement drum 105 is arranged is held by the separation preventing means 106 as described above, the segment arrangement drum 105 can be stably rotated. The servo motor 117, the rotation shaft of the servo motor 117, the small diameter gear fixed to the rotation shaft, the large diameter gear 123 meshing with the small diameter gear, and a control unit 49 described later that controls the servo motor 117 Each time the front leg 17b of the segment 17S is disposed, the index rotation mechanism is configured to rotate the segment disposition drum 105 by a predetermined angle (first predetermined angle).

As shown in FIGS. 30 and 31, the blade adjustment mechanism 118 has a ball screw portion 125 having a rotation axis parallel to the rotation axis 121 of the segment disposition drum 105, and is screwed with the ball screw portion 125 and parallel to the rotation axis. The nut portion 126 is slidable in the P (-) (+) direction, the servomotor 127 for rotationally driving the ball screw portion 125, and the base portion is fixed to the nut portion 126. In the slide member 128 sliding in the P (-) (+) direction, the engagement portion 129 fixed to the rotation shaft 121 and engaged with the convex portion at the tip of the slide member 128, and in the segment arrangement drum 105 And a plurality of (two in the illustrated example) hollow conical cams 130 (see FIG. 31) fixed to the rotation shaft 121.

The slide member 128 has a base fixed to the nut portion 126, and a pair of parallel arms 128a and 128b extending from the base along the ball screw portion 125. A pair of protrusions projecting inward is formed at the tip of the pair of arms 128a and 128b, respectively, and the pair of protrusions are engaged with the annular groove 129a of the engagement portion 129 in a cam follower manner. There is. As a result, even when the rotation shaft 121 and the engagement portion 129 are both rotated, the slide member 128 and the engagement portion 129 are connected under low friction. Therefore, when the servomotor 127 rotates and the ball screw portion 125 rotates, and thereby the nut portion 126 and the slide member 128 slide along the ball screw portion 125, the rotating shaft 121 slides in the sliding direction according to the sliding. Will move to

As shown in FIG. 31, each blade 108 of the segment arrangement drum 105 is formed with an obliquely extending groove 108a, and the conical cam 130 is slidably inserted in the groove 108a. Therefore, when the servomotor 127 rotates and the rotary shaft 121 moves in the P (-) direction, the blade 108 protrudes outward in the radial direction of the segment arrangement drum 105, and when the rotary shaft 121 moves in the P (+) direction 108 will be pulled in radially inward of the segment arrangement drum 105. Thus, by controlling the amount of rotation and the direction of rotation of the servomotor 127, the amount of protrusion of the blade 108 can be adjusted.

As shown in FIG. 29, the pushing mechanism 119 has a ball screw portion 131 having a rotation axis parallel to the rotation axis 121, and is screwed to the ball screw portion 131 and can slide in the P (-) (+) direction. A nut portion 132, a servomotor 133 for rotationally driving the ball screw portion 131, and a slide member 134 fixed to the nut portion 132 and moving in the P (-) (+) direction with the rotation of the ball screw portion 131; A pressing ring 135 is disposed slidably on the circumferential surface of the segment placement drum 105 in the axial direction (P (−) (+) direction) and engaged with the slide member 134.

The slide member 134 has a base fixed to the nut portion 132, and a pair of parallel parallel arms 134a and 134b extending from the base along the ball screw portion 131. A pair of projections projecting inward is formed at the tip of the pair of arms 134a and 134b, respectively, and the pair of projections are engaged with the annular groove 135a of the pressing ring 135 in a cam follower manner. . As a result, even if the pressing ring 135 is rotated by friction with the circumferential surface of the segment arrangement drum 105, the slide member 134 and the pressing ring 135 are connected under low friction. Accordingly, when the servomotor 133 rotates and the ball screw portion 131 rotates, and thereby the nut portion 132 and the slide member 134 slide along the ball screw portion 131, the segment arrangement drum 105 slides in accordance with the slide. It will move in the direction.

The work support 120 includes a base 136, a work placement portion 138 having a V-shaped recess 138a fixed to the base 136 via a support 137, and a pair of rails 136a formed on both sides of the upper surface of the base 136. And.

As shown in FIGS. 32 and 33, the separation preventing means 106 is disposed on the radial side of the segment arrangement drum 105 so as to face each other with the segment arrangement drum 105 interposed therebetween and extend in the vertical direction. It has arms 139A and 139B. The pair of arms 139A and 139B is rotatably supported with a shaft 140 provided at substantially the center of each arm as an arm fulcrum, and the upper end of the pair can contact and separate from the circumferential surface of the segment arrangement drum 105 Is configured as. The lower end portion of the arm 139A is connected to the rack member 141A sliding in the direction orthogonal to the P (-) (+) direction via a cam follower, and the lower end portion of the arm 139B is connected to the P (-) (+) direction A cam follower is connected to the rack member 141B which slides in the orthogonal direction. The rack member 141A and the rack member 141B are both meshed with the pinion gear 142, and are connected via the pinion gear 142. The rack member 141A is connected to the servomotor 143, and when the servomotor 143 rotates, not only the rack member 141A but also the rack member 141B slides, and as a result, the pair of arms 139A and 139B are synchronized. Rotate.

At the top of the pair of arms 139A and 139B, there is provided a pair of horizontal bars 144 which are respectively fixed so as to perpendicularly intersect with the pair of arms. A pair of holders 145 are respectively fixed to both ends of each of the pair of horizontal bars 144. Therefore, a total of two pairs of holders 145 are provided at both ends of the pair of horizontal bars 144. Two pairs of movable pulleys 146 for belts are rotatably supported and fixed to the two pairs of holders 145, respectively. Two fixed pulleys 147 are rotatably supported and fixed to the frame of the detachment prevention means 106, and two small diameter fixed pulleys 148 are rotatably supported and fixed, and further, the tension pulleys 149 are fixed pulleys. It is rotatably supported between 148 and fixed. One set of these two fixed pulleys 147, two small diameter fixed pulleys 148, and a tension pulley 149 are provided corresponding to the two pairs of movable pulleys 146.

One of the pair of belts 107 arranged in line in the axial direction of the segment arrangement drum 105 is a movable pulley 146 fixed to the holder 145, two fixed pulleys 147, and two small diameter fixed pulleys. 148 and a tension pulley 149, and is configured to cover the lower circumferential surface of the segment arrangement drum 105. The tension pulley 149 is connected to the air cylinder 151 via the support shaft 150. Since the tension pulley 149 is displaced in the vertical direction by the operation of the air cylinder 151, the contact pressure of the belt 107 with respect to the circumferential surface of the segment arrangement drum 105 can be variably adjusted. The other belt of the pair of belts 107 has the same configuration, and is configured to perform the same operation.

In each of the pair of arms 139A and 139B, a plurality of screw holes 139a are formed in two rows spaced apart in the vertical direction, whereby the vertical fixing position of the horizontal bar 144 can be adjusted. ing. As shown in FIG. 33, in each of the horizontal bars 144, two fixing holes 144a in the form of elongated holes extending vertically are formed, and the horizontal bars 144 are inserted by screws 144b inserted through the fixing holes 144a. Is fixed to the arm 139A or 139B so as to be finely adjustable in the vertical direction. By adjusting the fixed position in the vertical direction of the horizontal bar 144, it is possible to cope with changes in the diameter of the segment arrangement drum 105. The adjustment of the contact pressure of the pair of belts 107 with respect to the circumferential surface of the segment arrangement drum 105 can be adjusted independently for each belt.

Next, a configuration and an operation of inserting the coil assembled by the segment arrangement drum 105 into the core 152 in the manufacturing apparatus of the rotating electrical machine of the present embodiment will be described.

In the coil assembly unit 2, as described above, a plurality of coil segments 17S are arranged on the circumferential surface of the segment arrangement drum 105 to assemble a coil. Next, the assembled coil is inserted into the core 152 of the rotating electrical machine. In that case, first, the work support 120 in which the core 152 is set is connected to the base 116 of the coil assembly 2. FIG. 34 shows the state in which the core 152 is set on the workpiece support 120 and the workpiece support 120 is connected to the base 116 so that the assembly coil on the segment disposition drum 105 can be inserted into the core 152. That is, the core 152 is placed on the work placement portion 138 in a state where the work support 120 is separated from the base 116, and the cuff support 154 supporting the insertion guide unit 153 is from the P (-) direction of the work support 120. It is moved through the rails 136a to connect the ring-shaped insertion guide unit 153 and the core 152. Thereafter, the workpiece support 120 is connected to the base 116 of the coil assembly 2 so that the insertion guide unit 153 faces the segment disposition drum 105. In FIG. 34, the guide member 112 is not shown.

As shown in FIG. 35, the insertion guide unit 153 has a cuff support 154 on the side facing the segment placement drum 105, and has a recess 153a on the other side that engages with the core 152. The cuff support 154 is for protecting the cuff portion 155 of the insulating paper inserted in each slot of the core 152, and the cuff of the core 152 is provided between the plurality of protrusions 154a radially arranged along the circumferential direction. The part 155 is configured to be inserted. The plurality of protrusions 154a are configured to be simultaneously slidable in the radial direction by a drive mechanism (not shown).

In the segment arrangement drum 105, when insertion of a predetermined number of layers by a predetermined number of coil segments 17S is performed and coil assembly is completed, the servomotor 133 of the pushing mechanism 119 rotates and the slide member 134 moves in the P (+) direction. As it moves, the pressing ring 135 moves in the P (+) direction along the circumferential surface of the segment arrangement drum 105. A recess (not shown) is provided on the P (+) side of the pressing ring 135 for accommodating the coil end portion (crossover portion) side of the assembled coil over the entire circumferential direction. The assembly coil in which the coil end portion is accommodated in the recess moves along the circumferential surface of the segment arrangement drum 105, and as shown in FIG. 36, the coil end portion (crossover portion) of the assembly coil is inserted into the insertion guide unit 153. Be inserted. That is, the ends of the front and rear legs of each coil segment 17S enter between the projections 154a of the insertion guide unit 153. The servomotor 133 stops its rotational operation at the timing immediately before the coil end portion (crossover portion) of the assembled coil interferes with the blade 108 of the segment arrangement drum 105, or at the timing immediately before the pressing ring 135 strikes the detachment preventing means 106. The movement of the pressing ring 135 is stopped.

Since the coil end portion (crossover portion) of the assembly coil is inserted into the insertion guide unit 153, the segment arrangement drum 105 is in a double support state. In this double-supported state, the servomotor 117 of the blade adjustment mechanism 118 rotates, the slide member 128 (see FIG. 30) moves in the P (+) direction, and the blade 108 protrudes from the circumferential surface of the segment arrangement drum 105 It retracts to a position where it does not interfere with the movement of the pressing ring 135. Further, the servomotor 143 (see FIG. 32) of the detachment preventing means 106 rotates so that the two pairs of arms 139A and 139B open radially outward from the circumferential surface of the segment arrangement drum 105. The contact state of the belt 107 is released. After that, the detachment preventing means 106 is lowered so as not to disturb the movement of the pressing ring 135.

After the detachment preventing means 106 is lowered, the pressing ring 135 is moved in the P (+) direction, and the insertion of the assembly coil into the core 152 proceeds. The movement of the pressing ring 135 is stopped immediately before the coil end portion (crossover portion) of the assembled coil abuts on the cuff support 154 as shown in FIG. 37, and all the projections 154a of the cuff support 154 as shown in FIG. The cuff support 154 is opened outward by moving it radially outward.

Thereafter, the pressing ring 135 is advanced to a predetermined position, and the movement of the pressing ring 135 is stopped before the coil end portion (crossover portion) of the assembly coil abuts on the cuff support 154. The timing for stopping the movement of the pressure ring 135 and the timing for stopping the movement of advancing the pressure ring 135 by a predetermined distance after the cuff support 154 is opened are stopped based on numerical values stored in the memory of the control means 49 in advance. To be done. After the insertion is completed, the pressing ring 135 is returned to the original position (initial position) by the operation of the pushing mechanism 119. FIG. 38 shows a state in which insertion of the assembly coil in the core 152 is completed.

As described above, according to the coil assembly unit 2 of the present embodiment, the core is formed by pressing the assembled coil assembled by arranging a plurality of coil segments on the segment arrangement drum 105 in the axial direction of the segment arrangement drum 105 It can be inserted into 152. Therefore, after pulling out the segment assembly from the jig, it is not necessary to exchange the jig and the core and then insert the segment assembly into the core, which significantly increases the working efficiency in manufacturing the rotary electric machine. It can be improved. That is, according to the configuration of the present embodiment, when the assembly of the coil segment is completed, it is possible to immediately shift to the operation of inserting the core 152 as it is, unnecessary time for exchanging the jig and the core, etc. It can be omitted.

Next, the electrical configuration of the coil assembly unit 2 will be described. In the present embodiment, the coil assembly unit 2 includes the index rotation drive mechanism of the segment arrangement drum 105, the separation preventing means 106, the segment conveyance means 110, the blade adjustment mechanism 118, and the pushing mechanism 119. Amplification and drive circuit of the servomotor 117 of the index rotation drive mechanism, amplification and drive circuit of the servomotor 143 for opening and closing the pair of arms 139A and 139B of the detachment prevention means 106, and the chuck portion 111 of the segment transport means 110. Amplification and drive circuit of servomotor 161 for rotating, amplification and drive circuit of servomotor 127 for adjusting protrusion amount of blade 108, Amplification and drive circuit of servomotor 133 for pushing out assembly coil, air cylinder 151 And 167 drive circuit It is connected. Signal lines from encoders mechanically connected to the plurality of servomotors are connected to the amplification and drive circuits of the plurality of servomotors.

The PLC 46 and the second NC controller 48 insert the coil segment in the coil assembly unit 2 and insert the assembled coil into the core 152 based on the steps S1 and S8 in FIG. 12 and the steps shown in the flowchart in FIG. Control. Hereinafter, the operation of the coil assembly unit 2 will be described in detail using the flowcharts of FIGS. 12 and 39.

As described above, in step S1 of FIG. 12, the PLC 46 arranges the number and the number of layers of the coil segment on the segment arrangement drum 105, the index rotation amount, the rotation amount of the arms 139A and 139B of the separation preventing means 106, and A series of control data relating to the amount of protrusion, the amount of movement of the pressing ring 135, and the like are read from the memory and output to the second NC controller 48.

The second NC controller 48 develops the control data thus received, and executes NC control of the drive mechanism of the designated address. In the present embodiment, the important points are cutting and peeling of the covering insulation layer in the wire feeding portion 3, primary bending in the primary bending portion 4, secondary bending in the secondary bending portion 5, and assembly in the coil assembly portion 2. The point is that it is performed in units of coil segments based on the set control information. That is, cutting and insulating layer peeling are performed in accordance with set control information for a certain processed coil segment, and primary bending is performed in accordance with set control information for the same processed coil segment. For the processing coil segment, secondary bending is performed according to the set control information, and coil assembly is performed according to the set control information for the same processed coil segment. As a result, it is possible to consistently perform cutting and peeling of the wire and formation of the coil segment to coil assembly, so that the working efficiency is greatly improved. In addition, since it becomes unnecessary to store the formed coil segments and to select a required one from the stored coil segments, management becomes very easy.

In coil assembly, first, index control for arranging the coil segment 17S on the circumferential surface of the segment arrangement drum 105 is performed (step S8 in FIG. 12). It is detected by the detection sensor 170 that the first coil segment 17S, which is a processed coil segment, is conveyed by the segment conveyance means 110 and its front leg is inserted into the segment holding portion 109a of the reference point of the segment arrangement drum 105. When the signal is transmitted from the PLC 46, the servomotor 117 is rotationally driven to rotate the segment arrangement drum 105 in the counterclockwise direction shown in FIG. 24A by one slot (10 degrees in this embodiment). This operation is sequentially repeated, and when the arrangement of the coil segments 17S for a predetermined number of cycles is completed, the servomotor 127 is rotationally driven to project the blade 108 by a predetermined amount (step S11 in FIG. 39).

The detection sensor 170 in the present embodiment is desirably a distance determination sensor using a laser or the like. That is, as shown in FIG. 24A, a laser light emitting unit and a laser light receiving unit are disposed on the lower surface of the guide member 112, the laser light is irradiated from the light emitting unit to the segment holding unit at the reference point, and the reflected light is The distance is determined by receiving light. The PLC 46 can determine from the determined distance whether the first coil segment has been inserted or the second or subsequent coil segment has been inserted, and transmits the result to the second NC controller 48. In addition to the distance determination sensor, for example, a sensor that emits and receives color light may be provided. That is, on the lower surface of the guide member 112, a color light sensor including a line-shaped light emitting unit and a light receiving unit extended in the axial direction of the segment arrangement drum 105 is arranged in line with the distance determination sensor. The light is irradiated to the segment holding portion of the light receiving portion, and the reflected light is received by the light receiving portion. The PLC 46 calculates the spectral light intensity of the reflected light output from the detection sensor 170, and compares the obtained light intensity with the reference spectral light intensity range stored in advance. If the spectral light intensity detected and calculated falls within the set tolerance, it is determined that the front leg has been inserted and placed normally, and is transmitted to the second NC controller 48. Since the coil segment 17S is generally copper colored and is different from the color of the peripheral surface of the blade 108 or the segment arrangement drum 105, it can be distinguished from the reflected light from other than the front leg. It should be noted that the judgment as to whether or not the front leg is properly arranged is made by combining a photoelectric sensor such as a color sensor with an imaging device such as a charge coupled device (CCD) or a complementary metal oxide semiconductor device (CMOS). It is also good. According to the combination of sensors having different detection methods, detection errors can be reduced.

When coil segments 17S are arranged in a predetermined number of layers on segment arrangement drum 105 to form an assembly coil, second NC controller 48 starts NC control to insert the assembly coil into core 152 (FIG. 39). Step 12). That is, control data for inserting the assembly coil into the core 152 is expanded and output to the push-out mechanism 119, the blade adjustment mechanism 118, and the detachment prevention means 106 to start an insertion operation to rotationally drive the target servomotor.

First, the second NC controller 48 rotates the servomotor 133 of the pushing mechanism 119 to move the pressing ring 135 in the P (+) direction, and the end of the slot insertion portion of the assembly coil is inserted into the insertion guide unit 153. The insertion is made (step 13 of FIG. 39). This movement is stopped immediately before the coil end portion (crossover portion) of the assembled coil interferes with the blade 108 or immediately before the pressing ring 135 abuts against the detachment preventing means 106. Thereby, the segment arrangement | positioning drum 105 will be in a double support state. FIG. 36 shows this state.

Next, the second NC controller 48 rotationally drives the servomotor 127 of the blade adjustment mechanism 118 to retract the blade 108 from the circumferential surface of the segment arrangement drum 105 so as not to protrude, and the servomotor 143 of the detachment prevention means 106 To rotate the belt 107 away from the circumferential surface of the segment arrangement drum 105 and lower the separation preventing means 106 (step 14 in FIG. 39).

Next, the second NC controller 48 rotates the servomotor 133 of the push-out mechanism 119 to advance the pressing ring 135 in the P (+) direction, and the coil end portion (crossing portion) of the assembly coil It is made to stop just before contacting (Step 15 of FIG. 39). FIG. 37 shows this state.

Next, the second NC controller 48 controls the drive mechanism (not shown) to move all the projections 154a of the cuff support 154 radially outward to open the cuff support 154 (step 16 in FIG. 39).

Then, the second NC controller 48 rotationally drives the servomotor 133 of the pushing mechanism 119 to advance the pressing ring 135 to a predetermined position, thereby inserting the assembled coil into the core 152, ie, in the slot of the core 152. Annular insertion of the coil segments is complete (step 17 in FIG. 39). After insertion, the pressure ring 135 is returned to its original position. FIG. 38 shows this state.

Next, a manufacturing apparatus of a rotating electrical machine according to another embodiment of the present invention will be described with reference to FIGS. 40A to 41. In the present embodiment, as shown in FIG. 40A to FIG. 40D and FIG. 41, the guide means of the coil assembly portion has a two-stage configuration, and two types of coil segment crossover portions and coil widths are different from each other. The coil segment is also constructed. The configurations, operations, and effects of the other parts in the present embodiment are the same as those in the above-described embodiment, and thus the description thereof will be omitted, and the same components will be described using the same reference numerals.

As shown in FIGS. 40A and 41, the guide means 113 in this embodiment includes an outer guide member 114 and an inner guide member 115 positioned closer to the central axis C of the segment arrangement drum 105 than the outer guide member 114. Has a two-stage configuration. The outer guide member 114 and the inner guide member 115 are disposed above the segment arrangement drum 105. The configuration of each of the outer guide member 114 and the inner guide member 115 is basically the same as the configuration of the guide member 112 in the embodiment shown in FIG. That is, a plurality of (three in this example) narrow guide pieces and brackets 114b and 115b for supporting the guide pieces apart from each other are provided, and the brackets 114b and 115b are axes of the segment arrangement drum 105. The guide pieces are provided along the direction, and extend in the direction orthogonal to the brackets 114b and 115b, respectively. The brackets 114 b and 115 b are fixed to a frame (not shown). However, the outer guide member 114 is provided to guide the coil segment 17S having a large coil width and a large distance between the slot insertion portions 17b and 17c, and the inner guide member 115 is provided between the slot insertion portions 17d and 17e. Is provided to guide the coil segment 17SS having a small coil width.

The inner guide member 115 is configured such that the circumferential length of the guide surface 115 c is shorter than the circumferential length of the guide surface 114 c of the outer guide member 114. The coil segment 17S having a large coil width is held by the chuck portion 111 of the segment conveyance means 110 so that the front leg 17b passes below the inner guide member 115 and the rear leg 17c passes above the outer guide member 114. It is transported. When the segment placement drum 105 rotates and the front leg 17b reaches the segment holding portion of the reference point above the segment placement drum 105, it is lowered. In the coil segment 17SS having a small coil width, the front leg 17d passes below the inner guide member 115 and the rear leg 17e passes above the inner guide member 115 while being held by the chuck portion 111 of the segment transport means 110. It is transported. The front leg 17d is lowered when the segment placement drum 105 is index-rotated and reaches the segment holding portion of the reference point. When the guide member has a two-stage configuration, the detection sensor 170 is disposed on the lower surface of the inner guide member 115, and is configured to detect the front leg 17d of the coil segment 17SS.

In the present embodiment, the coil assembly is performed by alternately supplying the coil segment 17S having a large coil width and the coil segment 17SS having a small coil width. In FIG. 40B, the front leg 17b-1 of the coil segment 17S of the first coil width is inserted into the predetermined segment holding portion 109 of the segment arrangement drum 105, and then the leg 17c-1 is mounted on the outer guide member 114; The front leg 17d-1 of the second coil segment 17SS is inserted into the next segment holding portion 109 of the segment arrangement drum 105, and then the leg 17e-1 is mounted on the inner guide member 115, and the third coil segment 17S having a large coil width Front leg 17b-2 is inserted into the next segment holding portion 109 of the segment placement drum 105 and then the leg 17c-2 is placed on the outer guide member 114.

As the alternate arrangement of the coil segments 17S having a large coil width and the coil segments 17SS having a small coil width proceeds, as shown in FIG. 40C, the rear leg 17e-1 of the second coil segment 17SS having a small coil width is formed. , And is disposed prior to the rear leg 17c-1 of the first coil segment 17S having a large coil width. The circumferential length of the outer guide member 114 and the inner guide member 115 is set so that the rear legs fall at such timing.

FIG. 40D shows a state in which the arrangement of the first round is completed. The guide members may be configured in three or more stages to be able to cope with more complicated arrangement patterns.

As described above, in the present embodiment, as shown in FIG. 41, in the coil segments supplied to the coil assembly portion 2, the coil segments 17S having a large coil width and the coil segments 17SS having a small coil width are alternately arranged. ing. In this case, the rear legs (2 of the coil segments 17SS of the second and fourth smaller coils than the rear legs (1) and (3) of the coil segments 17S of the first and third arranged coil widths of large) ) And (4) become non-simple patterns placed first. That is, when ten coil segments 17S and 17SS are arranged and developed, the rear legs of the second coil segment 17SS, the first coil segment 17S, the fourth coil segment 17SS, and the third coil segment 17S are The seventh coil segment 17SS, the eighth coil segment 17S, the ninth coil segment 17SS, and the tenth coil segment 17S are respectively disposed on the front legs.

42 and 43 schematically show an example of a system configuration of a manufacturing apparatus of a rotating electrical machine of the present invention.

The manufacturing system shown in FIG. 42 is on the downstream side of the stator core pallet 180 containing the cores of a plurality of stators, which is an example of a rotating electrical machine, a core conveyance line 181, and the core conveyance line 181. The laser marker 182 for positioning and marking the core, and a plurality of insulating paper inserters 183 located on the downstream side of the laser marker 182 of the core transport line 181 and inserting insulating paper into the slots of the stator core, and located downstream of the core transport line 181 The stator conveyance line 184 and the stator conveyance line 184 are arranged to intersect (orthogonal) with the stator conveyance line 184 and wire cutting, insulation layer peeling, primary bending molding, secondary bending molding, coil assembly, and coil insertion to the core Production of a single rotating electrical machine that is a unitized coil supply line And a location 100.

Although not shown, a coil twist portion that twists the coil segment free end side (slot insertion portion end side) and a twisted portion are welded to the stator conveyance line 184 downstream of the rotary electric machine manufacturing apparatus 100. A weld or the like is arranged to make all the coil segments electrically conductive.

As described above, the coil supply line (the manufacturing apparatus 100 for the rotary electric machine) extends the wire supply part 3 for supplying a linear wire of a predetermined length from which the insulating layer at both ends is peeled off, Bending is performed at the primary bending portion 4 that performs primary bending in the same plane in a U-shape consisting of a pair of slot insertion portions and a transition portion that connects the pair of slot insertion portions, and bending at the primary bending portion 4 The secondary bending portion 5 which performs secondary bending of the formed primary bending formed body in the direction intersecting with the above-described same plane, and the coil segment which has been subjected to bending at the secondary bending portion 5 are arranged in an annular shape And a pushing mechanism 119 for pushing the coil assembled in the coil assembly 2 and inserting the coil into the slot of the stator core. In the initial stage of constructing a manufacturing facility, as in this system configuration example, only a single coil supply line can be provided to construct a small-sized manufacturing apparatus and reduce the initial investment.

In the manufacturing system shown in FIG. 43, a unitized coil supply line (the manufacturing apparatus 100 for a rotating electrical machine) is disposed so as to cross (orthogonal) a plurality of (six in this example) stator transport lines 184. In the early stages of construction of manufacturing facilities, as in the system configuration example shown in FIG. 42, only a single coil supply line can be provided to reduce the initial investment, but unitization can be achieved in response to increased demand for stators. It is possible to make an efficient capital investment to increase the number of coil supply lines and expand the scale of production. Since these coil supply lines (the manufacturing apparatus 100 for the rotary electric machine) are unitized and have the same specifications, if the production capacity can be verified for the first single coil supply line, the verification is not necessary in the later expansion.

It is difficult to invest in equipment without knowing exactly how much demand there is in manufacturing rotary electric machines, and the risk is large. If there is a gap between the expected demand and the actual demand, it is an overinvestment of facilities . However, as described above, according to the manufacturing system that increases the unitized coil supply line of the same specification according to the demand of the rotating electric machine, the manufacturing of the rotating electric machine can be carried out with minimum equipment investment, Since equipment for incremental production can be gradually increased according to the increase in demand, equipment investment without waste (less risk) becomes possible.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited to such specific embodiments, and the gist of the present invention described in the claims unless otherwise specified in the above description. Within the scope of the above, various modifications and changes are possible. The effects described in the embodiments of the present invention only exemplify the most preferable effects resulting from the present invention, and the effects according to the present invention are not limited to those described in the embodiments of the present invention .

DESCRIPTION OF SYMBOLS 1 Coil segment forming part 2 Coil assembly part 3 Wire rod supply part 4 Primary bending part 5 Secondary bending part 6 Wire rod 7 Bobbin 8 Feeding direction changing part 9a, 9b Roller pair 10 Peeling part 11 Cutting part 12 Transfer mechanism 13 Holding member 14A , 14B, 15A, 15B, 16A, 16B Jigs 17a, 17a 'Crossing portions 17b, 17c Slots 17A Primary bending molded bodies 14A-1, 14B-1, 15A-1, 15B-1, 16A-1, 16B- 1 Groove 14A-2, 14B-2, 15A-2, 15B-2, 16A-2, 16B-2 Edge part 14A-3, 14B-3, 15A-3, 15B-3, 16A-3, 16B- 3 chamfered portion 18 fixed base 19A, 19B guide rail 20A, 20B, 59 movable base 21, 27A, 27B, 28A, 28B, 60A, 60B, 61, 63A, 63B, 64 Drive mechanism 22, 29A, 29B, 35A, 35B, 65, 75, 79, 85, 99, 125, 131, 159 Ball screw portion 23, 30A, 30B, 36A, 36B, 66, 76, 80, 86, 87, 014, 126, 132, 160 Nuts 24, 31A, 37A, 31B, 68, 72, 78, 82, 89, 102, 117, 127, 133, 161 Servomotors 25, 71, 77, 77 81 Slider 26A, 26B, 128a, 128b, 134a, 134b, 139A, 139B Arm 32A, 32B, 88 Slide plate 33A, 33B, 92, 103, 168 Cam follower 34A, 34B Pivot plate 38A, 38B Pivot drive plate 39A, 39B Joint recess 41, 44 Center of turning 45 HM I
46 PLC
47 first NC controller 48 second NC controller 49 control unit 50 51 optical communication cables 53A, 53B, 54A, 54B pressing jig 53A-1, 53-B, 54A-1, 54B-1 pressing surface 53A- 2, 53A-3, 53B-2, 53B-3, 54A-2, 54A-3 bolt insertion holes 53A-4, 53B-4, 54A-4, 54B-4 corner portions 55, 56 pressing jig unit 58 fixed Base 58a Opening 62 Rotational base 73, 74, 83, 84 Moving plate 90, 95, 96 Rail member 91, 97, 98 Sliding member 93, 101a Engaging groove 94 Bracket 100 Rotary electric machine manufacturing device 101 Engaging member 105 segment arrangement drum 106 separation preventing means 107 belt 108 blade 108 a groove 108 b tapered surface 109, 09a segment holding portion 110 segment conveyance means 111 chuck portion 112, 113 guide member 112a guide piece 112b, 114b, 115b, 163 bracket 112c, 114c, 115c guide surface 113 guide means 114 outer guide member 115 inner guide member 116, 136, 157 Base 118 blade adjustment mechanism 119 extrusion mechanism 120 work support 121 rotation shaft 122 bearing 123 large diameter gear 124 receiving portion 128, 134 slide member 129 engaging portion 129a annular groove 130 conical cam 135 pressing ring 136a, 165 rail 137 support 138 work Mounting portion 138a Recess 140 140 Shaft 141A, 141B Rack member 142 Pinion gear 144 Horizontal bar 145 Holder 146 Movable pulley 147, 148 fixed pulley 149 tension pulley 150 support shaft 151, 167 air cylinder 152 core 153 insertion guide unit 154 cuff support 154a projection 155 cuff section 158 drive mechanism 162 slider 164 drive claw 164a recessed groove 166 turning base 170 detection sensor 180 stator core pallet 181 core Conveying line 182 Laser marker 183 Insulating paper inserter 184 Stator conveying line C Bending center line

Claims (16)

1. A coil segment forming portion for forming a linear wire of a predetermined length into a predetermined shape comprising a pair of slot insertion portions extending substantially parallel to each other and a transition portion connecting the pair of slot insertion portions; And a coil assembly unit for assembling the coil by arranging the coil segments formed by the coil segment formation unit in an annular shape, and the coil segment formation unit and the coil assembly unit are set according to the coil to be manufactured. An apparatus for manufacturing a rotating electrical machine, wherein molding and assembly are continuously performed in units of coil segments based on control information.
2. In the direction in which the coil segment forming portion intersects the same plane with a primary bending portion in which the wire rod is subjected to a primary bending process in the same plane and a primary bending forming body in which the bending process is performed in the primary bending portion. And a secondary bending portion for secondary bending, and the primary bending portion and the secondary bending portion are each coil for primary bending and secondary bending based on the set control information. The apparatus for manufacturing a rotating electrical machine according to claim 1, wherein the apparatus is configured to perform continuously in segment units.
3. The apparatus further comprises a wire supply unit for supplying a linear wire of a predetermined length, and the wire supply unit, the coil segment forming unit and the coil assembly unit supply coil segments based on the set control information. The apparatus for manufacturing a rotating electrical machine according to claim 1, wherein the forming and assembling are performed continuously in units of coil segments.
4. The coil assembly further includes a coil insertion mechanism for pushing the assembled coil assembled in the coil assembly in the axial direction of the assembled coil and inserting the coil into the slot of the core coaxially arranged with the assembled coil. The manufacturing apparatus of the rotary electric machine of any one of Claim 1 to 3.
5. A work supply line for supplying a stator or rotor having a core, and a coil supply line connected to the work supply line and having the coil segment forming portion, the coil assembly portion, and the coil insertion mechanism are provided. The rotary electric machine according to claim 4, wherein the coil insertion mechanism of the coil supply line is configured to insert the assembly coil into a slot of the core supplied from the work supply line. Production equipment.
6. The said coil supply line is unitized, The unit of this coil supply line is provided with two or more according to the demand of a rotary electric machine, The manufacturing apparatus of the rotary electric machine of Claim 5 characterized by the above-mentioned.
7. The primary bending portion is provided with a plurality of jigs arranged in the same plane and supporting the wire, and a plurality of jigs according to movement amounts respectively set according to the shape conditions of the coil segments to be formed. The manufacturing apparatus of the rotary electric machine according to claim 2, further comprising: a plurality of primary bending drive mechanisms which are respectively moved within the same plane so that the wire rod has the predetermined shape based on the plurality of primary bending drive mechanisms. .
8. The rotation according to claim 7, wherein the plurality of primary bending drive mechanisms are configured to turn or linearly move the plurality of jigs based on data of the set movement amount. Electric machine manufacturing equipment.
9. The secondary bending portions are disposed to face each other in a direction intersecting the same plane, and a plurality of pairs of pressing jigs that sandwich and press the transition portion, and the plurality of pairs of pressing jigs, A plurality of secondary bending drive mechanisms are provided, each of which is moved in the direction intersecting with the same plane based on the movement amount respectively set according to the shape condition of the coil segment to be formed. The manufacturing apparatus of the rotary electric machine of Claim 2.
10. The rotating electrical machine according to claim 9, wherein the plurality of secondary bending drive mechanisms are configured to move the plurality of pairs of pressing jigs based on data of the set movement amount. Production equipment.
11. The plurality of secondary bending drive mechanisms move the plurality of pairs of pressing jigs in a direction perpendicular to the same plane and / or in a direction oblique to the same plane, and intersect the same plane with the crossover section. The apparatus for manufacturing a rotating electrical machine according to claim 9, wherein the apparatus is configured to form a shift in the direction of movement.
12. A plurality of segment holding portions in each of which the coil assembly can insert the coil segments radially outward from each other, and a plurality of segment holding portions are annularly arranged along the circumferential direction; One segment holding portion of the plurality of segment holding portions is one slot insertion portion of the pair of slot insertion portions of each of the plurality of coil segments every time the segment arrangement body rotates by the first predetermined angle And the other slot inserting portion of the pair of slot inserting portions when the second slot inserting portion is rotated by a second predetermined angle from the insertion of the one slot inserting portion into the other of the plurality of segment holding portions And a guide means configured to guide and insert into one of the segment holding parts of .
13. A coil segment forming step of forming a linear wire having a predetermined length into a predetermined shape comprising a pair of slot insertion portions extending substantially parallel to each other and a transition portion connecting the pair of slot insertion portions; And a coil assembly process for assembling the coils by arranging the coil segments formed in the forming process in an annular shape, and the coil segment forming process and the coil assembly process are set according to the coil to be manufactured. A manufacturing method of a rotary electric machine characterized by performing forming and assembling continuously in each coil segment unit based on information.
14. The coil segment forming process includes a primary bending process in which the wire rod is subjected to a primary bending process in the same plane, and a primary bending molded body obtained by bending in the primary bending process in the direction crossing the same plane. And a secondary bending process for secondary bending, and the primary bending process and the secondary bending process are performed for each coil segment based on the set control information. The method for manufacturing a rotating electrical machine according to claim 13, wherein the method is performed continuously in units.
15. The method further comprises a wire feeding step of feeding a linear wire of a predetermined length, and the wire feeding step, the coil segment forming step and the coil assembling step feed coil segments based on the set control information. The method for manufacturing a rotating electrical machine according to claim 13, wherein forming and assembly are performed continuously in units of coil segments.
16. The method further includes a coil inserting step of extruding the assembled coil assembled in the coil assembling step in the axial direction of the assembled coil and inserting the coil into a slot of a core coaxially arranged with the assembled coil. The manufacturing method of the rotary electric machine of Claim 13.

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